连续与搭接螺旋折流板换热器理论分析与实验研究
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摘要
换热器是在化工、石油、轻工、冶金、能源与动力等许多工业部门中使用的一种通用工艺设备。在各种换热器中,管壳式换热器由于结构简单、制造成本低、可靠性高、适应性强等特点而应用最为广泛。鉴于管壳式换热器在工业领域中的重要作用,通过改进传统的壳程结构以提高其效率成为节能减排的重要途径,螺旋折流板换热器正是基于此而研究开发的一种新型的高效节能换热设备。
本文从理论分析、数值模拟与实验研究等方面对连续与搭接螺旋折流板换热器的结构设计与性能特点进行研究,开展的研究工作及所取得的主要研究成果如下：
对连续与搭接螺旋折流板的结构特点进行了分析,推导了螺旋角、搭接量、螺距之间的计算关系,得到了折流板结构参数的计算方法。基于一定的简化与假设,建立了螺旋层流流动的数学模型,对轴向、切向及径向速度分量的特点作了分析,对流体与折流板之间的受力情况作了研究。在此基础上,建立了螺旋折流板换热器壳程实际流动模型,将壳程实际螺旋流动分为螺旋流动主流流路、漏流流路、旁流流路等相互独立的流路,分别对各流路的形成原因、特点及对换热器性能的影响进行了分析。
在合理简化的基础上,建立连续与搭接螺旋折流板换热器计算区域的物理模型,设置合理的边界条件,使用RNG κ-ε湍流模型对换热器壳程与管程的流动与传热情况进行了数值模拟。提出了一种新的计算螺旋流动雷诺数的方法,能够较好地反映螺旋折流板换热器壳程流体流动状态。
螺旋角对连续与搭接螺旋折流板换热器各物理量分布及传热与阻力性能等具有相似的影响规律：壳程螺旋通道可分为入口阶段、螺旋流动阶段及出口阶段,螺旋角不同时,各阶段的变化规律不同；轴向速度随着径向距离的增大而降低,螺旋角越大,均匀性越好；同流量下壳程表面传热系数与压降均随螺旋角的增大而降低,而单位压降下的表面传热系数随螺旋角的增大而增加;熵产数随螺旋角的增大而降低,而且螺旋角越大,换热器最佳运行雷诺数越低。
搭接量是搭接螺旋折流板特有的结构参数。交错搭接时,轴向速度在搭接点前后呈现先减小、后增大的抛物线形分布；同流量下,随搭接量的增大,表面传热系数与压降均增大,而单位压降下的表面传热系数减小；熵产数与换热器最佳运行雷诺数均随搭接量的增大而增加。
通过连续与搭接螺旋折流板换热器数值模拟结果的对比发现,相邻搭接螺旋折流板之间的三角区与搭接区漏流导致壳程流动偏离连续螺旋流动,增大了流体的轴向反混,加剧了轴向速度在径向分布的不均匀性。存在与螺旋角有关的转折雷诺数,在转折雷诺数前后,连续螺旋折流板换热器与搭接螺旋折流板换热器不可逆损失的相对大小不同。
在对1/4扇形螺旋折流板换热器进行深入研究的基础上,提出了六分扇形螺旋折流板换热器,其折流板的1个螺距由6块六分扇形螺旋折流板组成。数值模拟结果表明,相邻折流板轴向周边重叠的结构有效地减轻了三角区漏流,轴向速度沿径向的分布更加均匀。与1/4扇形螺旋折流板换热器相比,六分扇形螺旋折流板换热器壳程表面传热系数更高,压降更低,同时熵产数更低,不可逆损失更小。从场协同理论的角度分析,新型搭接螺旋折流板结构使壳程速度场与温度梯度场以及速度场与压力梯度场之间均有着更好的协同性,从而实现高效低阻的强化传热目标。
拟合得到了连续螺旋折流板换热器、1/4扇形螺旋折流板换热器及六分扇形螺旋折流板换热器壳程努塞尔数关联式与壳程阻力因子关联式,为螺旋折流板换热器的设计与校核提供了参考依据。
通过搭建实验平台,对六分扇形螺旋折流板换热器进行了实验研究。结果表明,与弓形折流板换热器相比,六分扇形螺旋折流板换热器具有更好的壳程综合性能,通过实验值与模拟值的对比,验证了数值计算方法的可靠性。
The heat exchanger is the universal process equipment which is applied in various industrial sectors, such as chemical industry, petroleum, light industry, metallurgy, energy and power, etc. Shell-and-tube heat exchanger (STHX) has been the most comprehensive heat exchanger due to its simple construction, low manufacturing cost, high reliability, and excellent adaptability, etc. In view of the important role in industrial areas of STHX, to increase its efficiency by improving traditional shell-side structures becomes a crucial way for energy saving and emission reduction. On the basis of this way, shell-and-tube heat exchanger with helical baffles (STHXHB) is invented as novel energy efficient heat transfer equipment.
This paper adopts theoretical analysis, numerical simulation and experimental study to research structure design and performance of STHX with continuous helical baffles and STHX with overlapped helical baffles. Researches and main results are as follows:
The structural characteristics of STHX with continuous helical baffles and STHX with overlapped helical baffles are analyzed. The relationship among helix angle, overlap size and helix pitch is derived, and also the calculation method of geometric parameters of baffles is obtained. The mathematic model of shell-side laminar continuous helical flow is established based on certain simplifications and assumptions. The characteristics of velocity components of axial, tangential and radial are analyzed. The study of forces between fluid and baffles is made. Based on above researches, the model of shell-side actual flow is established. The shell-side actual helical flow can be divided into several independent flow channels, such as helical mainstream flow channel, leakage flow channel and bypass flow channel. The formation causes, characteristics and impacts on heat exchanger of each flow channel are studied respectively.
The physical models of computation domain of STHX with continuous helical baffles and STHX with overlapped helical baffles are established based on certain reasonable simplifications, and boundary conditions are properly defined. RNG k-ε turbulence model is applied to numerical simulate shell-side and tube-side flow and heat transfer of heat exchanger. New calculation method of shell-side Reynolds number is put forward which can better reflect the state of shell-side flow fluid.
The effects of helix angle on distributions of physical quantities and heat transfer and resistance characteristics are similar in STHX with continuous helical baffles and in STHX with overlapped helical baffles.Shell-side helical channel consists of inlet region, helical flow region and outlet region, and the variations of each region vary with helix angle. Axial velocity decreases along radial direction, and the larger helix angle is, the more uniform distribution is. Both shell-side heat transfer coefficient and pressure drop decrease with the increase of helix angle, whereas heat transfer coefficient per unit pressure drop increases with the increase of helix angle at certain mass flow rate. Entropy generation number decreases with the increase of helix angle, and the larger helix angle is, the lower optimum operation shell-side Reynolds number is.
Overlap size is the peculiar structural parameter of overlapped helical baffles. When baffles are connected in an overlapped manner, the variation trends of axial velocity are different before and after the overlap point, and it is parabolic distribution which first decreases and then increases. Both shell-side heat transfer coefficient and pressure drop increase with the increase of overlap size, whereas heat transfer coefficient per unit pressure drop decreases with the increase of overlap size at certain mass flow rate. Both entropy generation number and optimum operation shell-side Reynolds number increase with the increase of overlap size.
Comparing the simulation results between STHX with continuous helical baffles and STHX with overlapped helical baffles, it is found that the leakages from triangle zone and overlapped zone between two adjacent baffles cause shell-side flow deviates from continuous helical flow, which increases flow back mixing along radial direction, and exacerbates the non-uniform of radial distribution of axial velocity. There exists transition shell-side Reynolds number which is related with helix angle, and the relative size of irreversible loss in STHX with continuous helical baffles and in STHX with overlapped helical baffles is different before and after the transition shell-side Reynolds number.
A novel STHX with overlapped helical baffles is proposed based on thorough researches on STHX with quarter sector helical baffles, which consists of six sixth sector helical baffles one helix pitch. Simulation results show that the axial peripheral overlapped structure between two adjacent baffles can effectively reduce the leakage from triangle zone, which makes radial distribution of axial velocity more uniform. Shell-side heat transfer coefficient is higher, shell-side pressure drop is lower and entropy generation number is lower, so irreversible loss is also lower in STHX with sixth sector helical baffles compared with in STHX with quarter sector helical baffles. The novel overlapped structure makes both the synergy between velocity field and pressure gradient field and the synergy between velocity field and temperature gradient field better in shell-side from point of field synergy principle analysis.
Shell-side Nusselt number correlations and shell-side resistance factor correlations of STHX with continuous helical baffles, STHX with quarter sector helical baffles and STHX with sixth sector helical baffles are fitted, which can provide references for the heat exchanger design calculations.
STHX with sixth sector helical baffles is experimental studied by setting up experimental apparatus. Results show that STHX with sixth sector helical baffles has better shell-side comprehensive performance than STHX with segmental baffles. The reliability of numerical method is verified by comparing experimental values and numerical values.
本文从理论分析、数值模拟与实验研究等方面对连续与搭接螺旋折流板换热器的结构设计与性能特点进行研究,开展的研究工作及所取得的主要研究成果如下：
对连续与搭接螺旋折流板的结构特点进行了分析,推导了螺旋角、搭接量、螺距之间的计算关系,得到了折流板结构参数的计算方法。基于一定的简化与假设,建立了螺旋层流流动的数学模型,对轴向、切向及径向速度分量的特点作了分析,对流体与折流板之间的受力情况作了研究。在此基础上,建立了螺旋折流板换热器壳程实际流动模型,将壳程实际螺旋流动分为螺旋流动主流流路、漏流流路、旁流流路等相互独立的流路,分别对各流路的形成原因、特点及对换热器性能的影响进行了分析。
在合理简化的基础上,建立连续与搭接螺旋折流板换热器计算区域的物理模型,设置合理的边界条件,使用RNG κ-ε湍流模型对换热器壳程与管程的流动与传热情况进行了数值模拟。提出了一种新的计算螺旋流动雷诺数的方法,能够较好地反映螺旋折流板换热器壳程流体流动状态。
螺旋角对连续与搭接螺旋折流板换热器各物理量分布及传热与阻力性能等具有相似的影响规律：壳程螺旋通道可分为入口阶段、螺旋流动阶段及出口阶段,螺旋角不同时,各阶段的变化规律不同；轴向速度随着径向距离的增大而降低,螺旋角越大,均匀性越好；同流量下壳程表面传热系数与压降均随螺旋角的增大而降低,而单位压降下的表面传热系数随螺旋角的增大而增加;熵产数随螺旋角的增大而降低,而且螺旋角越大,换热器最佳运行雷诺数越低。
搭接量是搭接螺旋折流板特有的结构参数。交错搭接时,轴向速度在搭接点前后呈现先减小、后增大的抛物线形分布；同流量下,随搭接量的增大,表面传热系数与压降均增大,而单位压降下的表面传热系数减小；熵产数与换热器最佳运行雷诺数均随搭接量的增大而增加。
通过连续与搭接螺旋折流板换热器数值模拟结果的对比发现,相邻搭接螺旋折流板之间的三角区与搭接区漏流导致壳程流动偏离连续螺旋流动,增大了流体的轴向反混,加剧了轴向速度在径向分布的不均匀性。存在与螺旋角有关的转折雷诺数,在转折雷诺数前后,连续螺旋折流板换热器与搭接螺旋折流板换热器不可逆损失的相对大小不同。
在对1/4扇形螺旋折流板换热器进行深入研究的基础上,提出了六分扇形螺旋折流板换热器,其折流板的1个螺距由6块六分扇形螺旋折流板组成。数值模拟结果表明,相邻折流板轴向周边重叠的结构有效地减轻了三角区漏流,轴向速度沿径向的分布更加均匀。与1/4扇形螺旋折流板换热器相比,六分扇形螺旋折流板换热器壳程表面传热系数更高,压降更低,同时熵产数更低,不可逆损失更小。从场协同理论的角度分析,新型搭接螺旋折流板结构使壳程速度场与温度梯度场以及速度场与压力梯度场之间均有着更好的协同性,从而实现高效低阻的强化传热目标。
拟合得到了连续螺旋折流板换热器、1/4扇形螺旋折流板换热器及六分扇形螺旋折流板换热器壳程努塞尔数关联式与壳程阻力因子关联式,为螺旋折流板换热器的设计与校核提供了参考依据。
通过搭建实验平台,对六分扇形螺旋折流板换热器进行了实验研究。结果表明,与弓形折流板换热器相比,六分扇形螺旋折流板换热器具有更好的壳程综合性能,通过实验值与模拟值的对比,验证了数值计算方法的可靠性。
The heat exchanger is the universal process equipment which is applied in various industrial sectors, such as chemical industry, petroleum, light industry, metallurgy, energy and power, etc. Shell-and-tube heat exchanger (STHX) has been the most comprehensive heat exchanger due to its simple construction, low manufacturing cost, high reliability, and excellent adaptability, etc. In view of the important role in industrial areas of STHX, to increase its efficiency by improving traditional shell-side structures becomes a crucial way for energy saving and emission reduction. On the basis of this way, shell-and-tube heat exchanger with helical baffles (STHXHB) is invented as novel energy efficient heat transfer equipment.
This paper adopts theoretical analysis, numerical simulation and experimental study to research structure design and performance of STHX with continuous helical baffles and STHX with overlapped helical baffles. Researches and main results are as follows:
The structural characteristics of STHX with continuous helical baffles and STHX with overlapped helical baffles are analyzed. The relationship among helix angle, overlap size and helix pitch is derived, and also the calculation method of geometric parameters of baffles is obtained. The mathematic model of shell-side laminar continuous helical flow is established based on certain simplifications and assumptions. The characteristics of velocity components of axial, tangential and radial are analyzed. The study of forces between fluid and baffles is made. Based on above researches, the model of shell-side actual flow is established. The shell-side actual helical flow can be divided into several independent flow channels, such as helical mainstream flow channel, leakage flow channel and bypass flow channel. The formation causes, characteristics and impacts on heat exchanger of each flow channel are studied respectively.
The physical models of computation domain of STHX with continuous helical baffles and STHX with overlapped helical baffles are established based on certain reasonable simplifications, and boundary conditions are properly defined. RNG k-ε turbulence model is applied to numerical simulate shell-side and tube-side flow and heat transfer of heat exchanger. New calculation method of shell-side Reynolds number is put forward which can better reflect the state of shell-side flow fluid.
The effects of helix angle on distributions of physical quantities and heat transfer and resistance characteristics are similar in STHX with continuous helical baffles and in STHX with overlapped helical baffles.Shell-side helical channel consists of inlet region, helical flow region and outlet region, and the variations of each region vary with helix angle. Axial velocity decreases along radial direction, and the larger helix angle is, the more uniform distribution is. Both shell-side heat transfer coefficient and pressure drop decrease with the increase of helix angle, whereas heat transfer coefficient per unit pressure drop increases with the increase of helix angle at certain mass flow rate. Entropy generation number decreases with the increase of helix angle, and the larger helix angle is, the lower optimum operation shell-side Reynolds number is.
Overlap size is the peculiar structural parameter of overlapped helical baffles. When baffles are connected in an overlapped manner, the variation trends of axial velocity are different before and after the overlap point, and it is parabolic distribution which first decreases and then increases. Both shell-side heat transfer coefficient and pressure drop increase with the increase of overlap size, whereas heat transfer coefficient per unit pressure drop decreases with the increase of overlap size at certain mass flow rate. Both entropy generation number and optimum operation shell-side Reynolds number increase with the increase of overlap size.
Comparing the simulation results between STHX with continuous helical baffles and STHX with overlapped helical baffles, it is found that the leakages from triangle zone and overlapped zone between two adjacent baffles cause shell-side flow deviates from continuous helical flow, which increases flow back mixing along radial direction, and exacerbates the non-uniform of radial distribution of axial velocity. There exists transition shell-side Reynolds number which is related with helix angle, and the relative size of irreversible loss in STHX with continuous helical baffles and in STHX with overlapped helical baffles is different before and after the transition shell-side Reynolds number.
A novel STHX with overlapped helical baffles is proposed based on thorough researches on STHX with quarter sector helical baffles, which consists of six sixth sector helical baffles one helix pitch. Simulation results show that the axial peripheral overlapped structure between two adjacent baffles can effectively reduce the leakage from triangle zone, which makes radial distribution of axial velocity more uniform. Shell-side heat transfer coefficient is higher, shell-side pressure drop is lower and entropy generation number is lower, so irreversible loss is also lower in STHX with sixth sector helical baffles compared with in STHX with quarter sector helical baffles. The novel overlapped structure makes both the synergy between velocity field and pressure gradient field and the synergy between velocity field and temperature gradient field better in shell-side from point of field synergy principle analysis.
Shell-side Nusselt number correlations and shell-side resistance factor correlations of STHX with continuous helical baffles, STHX with quarter sector helical baffles and STHX with sixth sector helical baffles are fitted, which can provide references for the heat exchanger design calculations.
STHX with sixth sector helical baffles is experimental studied by setting up experimental apparatus. Results show that STHX with sixth sector helical baffles has better shell-side comprehensive performance than STHX with segmental baffles. The reliability of numerical method is verified by comparing experimental values and numerical values.
引文
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