摘要
换热器是实现不同介质之间热量传递的通用设备,既是工艺过程装置,也是余热回收设备,广泛应用于电力、冶金、化工、食品等工业部门,以及城市集中供热系统。通常情况,换热器产业的发展状况及水平与一个国家或地区的经济发展程度、社会的能源利用方式密切相关,同时也直接影响了能源的综合利用效率。我国正处于经济持续快速发展阶段,城市化进程迅速,也必然伴随着能源的大量消耗,这无疑给换热器行业带来巨大的机遇与挑战。
目前,我国的能源利用效率约为33%,与发达国家相比还相对偏低。主要原因之一是约占我国能源消费总量70%的工业领域存在着大量的工业余热(废热),特别是大量较低品位的余热资源没有得到有效地回收和利用。与此同时,我国的能源需求和消耗却在不断增加。其中,与人们日常生活密切相关的就是随着城市化进程而来的城市民用能源需求的大幅增加。近十年来,我国一直处于房屋建筑的高峰期,年施工面积增长率约为12.8%～26.6%,有关城市建设的相关问题随之产生。比如,对于我国广大地区,尤其是北方城市,保证居民冬季采暖是一巨大困扰,发展集中供热是一种必然选择。不仅如此,人们对住宅的舒适度要求同样发生着显著变化。冬季供暖不再是人们唯一的热能需求,小区住宅热水供应也正在逐渐成为一种生活必须的能源消耗,这无疑对能源供给,以及现有的换热设备与技术提出了新的要求。
事实上,随着人们对热传递过程研究与应用的认识不断深入,发现无论是工业领域,还是民用领域,都存在着诸多的品位不同的热能之间的热交换过程。其中,既涉及冷却、加热过程,亦或是多种介质实现对某一工作介质的热控制等。从某种意义上说,发展多介质换热设备符合科学用能的观点,无论在有效回收利用低品位的热能方面,还是在合理分配使用较高品位热能方面都具有其积极的意义。与此同时,多介质换热设备还具有提升系统的紧凑程度,占地面积小,设备投入少,使用灵活等优点。
板式换热器是一种重要的通用设备,具有传热系数高,结构紧凑等优点,能够满足较低温差下的热传递过程。在我国,板式换热器的生产开始于上世纪60年代,目前在很多领域得到了广泛地应用。其中,每年用于城市集中供热系统的可拆卸式板式换热器约占相关产品总数的70%左右。
换热板是板式换热器的关键部件,其结构与布置、波纹形式及参数直接决定了换热介质的流动形式,影响了换热器的换热及阻力性能,是板式换热器研究的重点和难点。从1930年出现由薄金属板压制的波纹板片,实现了板式换热器跨越发展,至今已发展了水平平直波纹、竖直波纹、人字形波纹、斜波纹等多种常用波纹板片。其中,以人字形波纹板片的应用最为广泛,研究也最为深入。人字形板式换热器在应用表现出高效紧凑的显著优点,同时表现出流动阻力大的不足,国内外很多学者致力于此方面的研究,发展新的板型也成为当前板式换热器研究的重要方向之一。
目前,板式换热器在我国的生产已极为普遍,但与国际先进水平相比,还有很大的差距,表现为或者是一种低水平重复,或者是一种简单模仿。这种差距主要体现在板片厚度、板片波纹形式、设计方式等方面的差异,以及由于以上原因造成的换热器性能上的差距。如化工领域的换热设备,我国换热设备的传热系数一般只及发达国家同类设备20%-50%。一个主要原因就是相关的研究数据一直受到国外垄断,自主研发还缺乏创新,缺乏先进的设计方法和相应的选型软件等。与此同时,在强化传热技术研究方面,尽管强化传热的意义和一些具体的方式(如三维肋、涡流发生器等)已被人们接受与理解和应用,但对强化传热效果的评价及强化传热作用的理论分析却一直未能找到一种恰当表达方式。因此,强化传热的研究和高效低耗的节能换热设备研究还相对的分散,没有一个统一标准,高效节能换热设备的设计与优化缺乏统一的理论指导,也在一定程度了制约了板式换热器的发展。
基于以上情况的综述,本文首先分析了已有的常用换热器性能评价指标。认为传统的换热器评价指标的共同特点是以热量的传递速率、阻力系数的大小,或其综合指数来评判对流换热过程的优劣,但对于传热过程的优化却没有一个清晰的表达,很难用于换热设备的优化设计。并且,传统的强化传热技术更多的是凭借经验进行开发和设计,往往是换热得到强化的同时,流动阻力增加更为明显,并不节能。此外,热力学第二定律作为一种重要的评价标准,考虑了由流动和传热过程中引起不可逆耗散为目标函数,形成了熵产最小化方法,为换热设备的优化提供了一种理论上的可能,但在换热器优化过程中,发现存在所谓的“熵产悖论”和某些矛盾。因此,以熵产最小为目标函数进行换热器的优化和换热器的性能评价,仍存在不完善的地方。
鉴于以上的换热设备性能评价及优化理论的有关情况,对过增元教授提出的传热强化的场协同原理及其在换热器设计优化中的应用进行了分析。通过从单项对流换热的机理,到对流换热的场协同理论在换热设备优化设计的应用完整的介绍和分析,认为场协同理论不仅能够对已有的传统强化传热理论有一个统一的解释,而且能够为对流换热的强化研究提供新的思路,为高效节能的传热强化新技术的研究提供理论基础,能够实现在场协同理论的指导下,研发的强化传热技术,在某些条件下实现了传热增加的倍率大于阻力增加的倍率。同时,笔者认为,场协同理论的建立为后续研究留下了空间,对于更复杂也更重要的换热设备和换热系统中的场协同理论有待于进一步的拓展。尽管场协同理论为开发新的换热设备节能技术指出了方向,却仍然不能为传热元件和换热设备的优化提供可量化的目标函数和设计准则。为此,进一步讨论和分析了过增元教授在场协同理论基础上提出的火积耗散理论,认为火积耗散理论不仅能够在一定范围内证明场协同理论的正确性,而在评价换热性能及进行优化设计方面具有重要的价值，对其在多介质板式换热器性能分析中的应用进行了相关分析,对指导该类换热器的设计优化奠定了基础。
本文以在国际大科学工程阿尔法磁谱仪(AMS)项目中提出并得到很好应用的新型多介质换热设备结构为出发点,着眼于民用领域,分析了球面扰流单元的传热与阻力性能,进行了相关设计,并以单对球凸面和单对球凹面的矩形通道进行了数值分析,验证了其迎风面能够减小局部场协同角的作用。介绍了球面不连续波的相关设计及其构成的板式换热器结构。该种新型换热板片波纹由球凸面和球凹面相间布置,在板间通道内,球凸面两两相对,顶点接触构成有效的支撑点；换热板的外形为正六边形,板片的六个顶角布置了三对进出口,能够满足两种介质或三种介质同时换热。该种新型的换热板的六个端口的球凸面与球凹面均匀布置,力求避免由于端口设计不合理带来的流场分布不均现象的产生。
在对球面不连续波纹的正六边形板式换热器进行两流体换热和三流体换热的数值模拟过程中,讨论了新型换热板在顺流和逆流状态下的性能。与波纹倾角为60。的人字形板式换热器进行比较,单位压降下的综合传热性能较优。在数值模拟的基础上拟合了球面不连续波纹板式换热器的传热准则式和摩擦系数准则式。通过对换热器内流场、温度场、压力场图形分析,认为板间流道的流动均匀,无流动死区,端口流场分布合理；不连续球面波纹起到了强化了传热的作用,同时具有较好的阻力性能。在球凸的迎风面和球凹的迎风面呈现传热得到强化的表现,并且其作用在相邻流道实现互补。
对于多介质换热设备而言,流道排列形式相对于两介质换热而言要复杂的多,流道排列形式的不同,传热性能差别较大。本文在针对两介质换热过程提出的火积耗散数的概念,发展为应用于多介质换热的火积耗散数,并进行了流道排列方式的初步研究。分析认为对于多介质换热过程,流道的布置对换热器的性能影响较大。在相同的初始条件下,随着流道数量的增加,火积耗散数降低,总的阻力损失也降低；在相同流道数量条件下,不同的排列形式对应的流体阻力差别不大,而火积耗散数差别较大。本文还分析了获得较优流道布置的途径。
在数值模拟的基础上,搭建了换热器传热与阻力性能综合实验平台,对球面不连续波纹板式换热器进行了水-水换热实验研究与分析。应用等流速法,对实验数据进行了回归,得到了传热及阻力准则式。实验数据分析,由球凸面和球凹面构成不连续波纹的新型换热板,换热性能优于BR1型人字形换热板,阻力特性明显优于目前常用的波纹倾角为60。的人字形板。分析球面波纹强化传热的机理,认为球面波纹能够减小局部场协同角,提高了板间流场与温度场的协同程度。
以上研究与分析为该种新型板式换热器的工程实际应用奠定了一定的基础。
The heat exchanger is the common equipment to transfer heat between diffirent media, it can work as process device and also heat recovery equipment. Heat exchangers are widely utilized in Power, Metallurgy, Chemical, Food and other industrical sectors, as well as the urban central heating system. Usually, the level of the heat exchangers industry is closely related to the economy development level of the country or region, and directly affects the energy utilization efiiciency. China is in a sustained and rapid economic development stage, with the rapid urbanization, and the large number of energy consumption, which will undoubtedly bring great opportunities and challenges to the heat exchanger industrys.
Compared with developed countries, Chian's energy utilization efficiency is still relative low now(about33%).One of the main reasons is a large amount of industrial waste heat in the industrial sector which used up about70%of Chian's total energy consumption, in particular, a large number of lower-grade waste heat resources are not effectively recovered and utilized. At the same time, China's energy demand and consumption are increasing. Where, the urban civilian energy needs related with people's daily life are increasing significently with the urbanization. Over the past decade, China has been in the peak period of the constructions, the growth rate of the construction area is about12.8%～26.6%per year, so many related issues with the unban construction are caused. For example, China's vast regions, especially in the northern cities, it is an enormous distress to ensure the residents heating in winter, to develop the central heating is an inevitable choice. Moreover, residential comfort requirements are significantly improving as the same time. Heating in winter is no the noly heat demand, hot water supply of residential homes is gradually becming the daily necessary energy consumption, which propose the new requirements undoubtedly for the energy supply, as well as the existing heat transfer equipments and technologies.
In fact, with the deep understanding for the heat transfer process research and application, it is founded that the heat exchange processes with the different grade exist in the industrial areas or civilian areas. Where, involve cooling, heating precess, or thermal control with one working medium with multi-media. In a sense, the development of multi-media heat transfer equipment is in line with the point of view of scientific utilization of energy, and has its positive significance in terms of the aspects of the effective recycling low-grade heat, or in the reasonable distributiong of higher grade heat. At the same time, the multi-media heat exchanger equipments also have many advantages, such as the high compactness, small footprint, less investment in equipment, as well as flexible use.
The plate heat exchangers are the important common equipment, having the high heat transfer coefficient, and the compact structure, possible to meet the heat transfer process for low temperature difference. In China, the production of plate heat exchanger began in the1960s, and had been widely used in many areas. Where, the detachable plate heat exchangers annually for urban central heating accounte for about70%of the total number of related products.
The heat exchanger plate is key components, its structure and arrangement, the wave form and parameters directly determine the heat transfer media flowing form, affect the heat transfer and resistance properties of the plate heat exchanger, are the study emphasis and difficulty at the same time. The thin metal corrugated plate were occured in1930, and then generated the plate heat exchangers' leaps and bounds development, and now has developed straight corrugation, vertical corrugation, chevron corrugation, cross corrugation commonly used. At present, the chevron corrugated paltes are the most widely used and most in-depth study. Chevron plate heat exchanger in the application shows the significant performance advantages of high efficience and compact, and also the lack of high flow resistance, many domestic and abroad scholars focus the research on this area, developing the new type of plate become one of the important research direction.
At present, the production of plate heat exchangers in China has been extremely common, but compared with the international advanced level, gaps are exist, most appear a kind of low-level redundant, or simple imitation. The gap is mainly reflected differences in the plate thickness, wave form, and the design, as well as the gap caused on the heat exchanger performance due to the above reasons. For example, heat transfer coefficient of China's chemical heat transfer equipments just reaches20%to50%of the developed countries generally similar equipment. A major reason is that the research data has been monopolized by foreign companies, lacking innovation of independent research and development, lacking advanced design methods and the appropriate selection software. At the same time, the enhanced heat transfer technologies and some specific ways (3D rib, vortex generators, etc.) have been accepted, understand and applicated, but the evaluation of the heat transfer enhancement and theoretical analysis of the heat transfer effect have no an appropriate expression. Therefore, the heat transfer enhancement research, high efficiency, low consumption energy-saving heat transfer equipment research are also relatively scattered, without an unified standard, high efficient heat transfer equipment design and optimization lacked an unified theoretical guidance, and also constrained the development of plate heat exchangers.
Based on the above review, firstly the commonly used heat exchanger performance evaluation criterias were this analyzed in this paper. The common characteristics of the traditional evaluation of the heat exchanger to evaluate the advantages and disadvantages of the convective heat transfer process with the heat transfer rate, the pressure drop coefficient, or the composite index, but lack of a clear expression of the heat transfer process, so it is difficult to optimize heat transfer equipment design. And the enhanced heat transfer technologies are mostly developed according to the experience, the flow resistance often increases more obviously when the heat exchangers have been strengthened at the same time, which is not energy-efficient. In addition, the second law of thermodynamics is considered as an important evaluation criteria, considering the irreversible dissipation caused by the flow and heat transfer processes as the objective function, forming the entropy generation minimization method, providing a theoretical possibility for the optimization of heat transfer equipmenton, but application in the heat exchanger optimization process, the so-called "entropy production paradox" and some contradictions exist. Therefore, there are still imperfect for the minimum entropy generation as the objective function for the optimization of the heat exchangers and heat exchanger performance evaluation.
In view of the above heat transfer equipment performance evaluation and optimization theory, the field synergy principle for heat transfer enhancement by Professor GUO Zengyuan and the application on the design optimization were analysised in this paper. According to the comprehensive introduction and analysis of the single phase convective heat transfer mechanism amd the application of the convective heat transfer field synergy theory for the heat exchangers optimize design, and that the field synergy theory can not only strengthen the existing traditional heat transfer theory a unified interpretation, the field synergy theory is proved that it can not only give one unified explanation for the existing traditional theory of transfer enhancement, but also provide new ideas for the study of convective heat transfer enhancement, a theoretical basis for the research of high-efficient and energy saving heat transfer enhancement trchnologies. It can be achieved under the guidance of the field synergy theory, to research and develop some enhanced heat transfer technologies, in which the heat transfer increase rate is greater than the resistance increase rate under some certain conditions. The same time, actually the field synergy theory leaves some space for the following study, for the more complex and more important heat transfer equipment and system, the further expansion is needed. Field synergy theory pointed out the direction for the development of new energy-saving technologies of heat transfer equipment, but it still can not provide a quantifiable target target function and design guidelines for the optimization of heat transfer components and equipments. For this reason, the further discussion and analysis for the entransy dissipation theory provided by Professor GUO Zengyuan carried on, the entransy dissipation theory not only can proved field synergy theory correctness within a certain range, but also the important value in the evaluation of heat exchangers performance and optimization design. Application analysis for the multi-media plate heat exchangers was performanced in this paper, which build the foundation for the guidance of such heat exchanger design optimization.
Based on a kind of novel multi-media heat exchanger invented and applied in the international large project Alpha Magnetic Spectrometer (AMS), accounting for utilization for this novel heat exchanger in the civil areas, analyzed the heat transfer efficiency and resistance characteristic for the spherical wave, and some design was performed. In addition, numerical analysis carried on for the single couple convex sphere wave and concave sphere wave in the rectangular channel, verify the windward side of the sphere wave form reduces the local field synergy angle, and play the role of reducing the local field synergy angle in the tail region alternately. The nolve plate with discontinuous structure wave combined with convex sphere and concave sphere sepatately. In the channels, convex sphere and concave sphere between adjacent plates are in pairs separately to form the flow channel and the vertexes of convex sphere between adjacent plates contact with the pairs, which become effective support points evenly distributed to meet the demand for pressure, and the plate is regular hexagon, three pairs of import and export were arranged at the six top corner of the plate, to meet the two or three media heat exchanger at the same time. For the design of entrance diversion area, convex sphere and concave sphere were evenly arranged at six import and export port, so uneven distribution of the flow field due to the port design could be avoided as possible.
Applying the CFD software, the numerical simulation for the new regular hexagon with spherical discontinuous corrugated plate heat exchanger was performed in this paper, consisting of two-fluid and three-fluid heat exchanger. The performance of the novel heat exchanger plate in the state of parallel flow and counter flow was discussed. Compared with60°chevron-type plate heat exchanger, the regular hexagonal plate heat exchanger is better in the aspect of comprehensive performance with the criterion of the overall heat transfer coefficient per unit pressure drop. Correlations on heat reansfer and friction factor were also summaried based on the numerical simulation. According to the analysis with the Graphices of the flow field, temperature field, pressure field, it is certified that the flow in the channel has the uniform morphology without flow dead zone, and the port flow field distribution is reasonable. The spherical wave played the role to strengthen the heat transfer, but also has better resistance properties. The heat transfer is enhanced on the windward sides of convex sphere and concave sphere, and their roles are complementary in the adjacent flow channels.
For the multi-media heat transfer equipments, arrangement of flow channels is more relative complex than the heat transfer between two media; furthermore, the heat transfer performance has larger difference for different arrangement of flow channels. According to the concept of entransy dissipation number, for two media heat exchanger process, the entransy dissipative number for multi-media heat exchanger process was analyzed, and the study for flow channels arrangement was performance. For the multi-media heat transfer process, the analysis shows that the arrangement of the flow channels has biger impact on the performance of the heat exchanger. Under the same initial conditions, the entransy dissipation number and the total loss resistance of the heat exchanger reduce with the number of flow channels increasing; for the same number of flow channels, the fluid resistance is little difference in the quantity for the different arrangement, but the entransy dissipation number has big difference. The ways to get a better arrangement of flow channels was analyzed in this paper.
The heat transfer and pressure drop performance comprehensive experimental platform was built on the basis of numerical simulation, and the water-water heat exchanger experimental research and analysis were perfoumanced for this novel plate heat exchanger. Equal velocity method was applyed, the regression of the experimental data was performance, and the correlations on heat reansfer and friction factor were also summaried. Analyzing the experimental data, that show that the novel plate with discontinuous structure consisting of convex sphere and concave sphere has the better heat transfer performance than that of the BR1chevron plate heat exchanger, and its resistance characteristics are superior to those of the normally used60-degree plate heat exchanger. The mechanism analysis of heat transfer enhancement shows that the spherical wave structure can reduce the local field synergy angle, so as to improve the field synergy degree of velocity vector and temperature gradient vector.
The above analysis for this novel plate heat exchanger provided some useful data and ideas for the engineering application.
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