锯齿螺旋翅片管束强化换热特性研究
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摘要
与传统的连续螺旋翅片管相比,锯齿螺旋翅片管制作简便、翅化比大且换热更强,已在联合循环余热锅炉等大型烟气热能回收装置中得到应用。但当前对其强化换热特性的基础研究较少,以往相关研究中不同研究者所得结论也不尽一致,制约了该换热管型的有效使用与广泛应用。本文在分析锯齿螺旋翅片管束强化换热机理的基础上,对锯齿螺旋翅片管错列管束的强化换热特性进行了较为全面的实验与数值模拟研究。
     在高温回流传热风洞中对12个锯齿螺旋翅片管束进行了实验研究,获得了横向管距、纵向管距及翅片间距在Re=4000~30000范围对管束换热特性和阻力特性的影响,并提出了相应的管束换热及阻力计算关联式,为相关工程提供了大量基础数据和设计依据。利用Fluent软件对10个实验管束的翅侧流动与换热特性进行了数值模拟,并根据实验结果对本文数值模拟方法及模拟结果进行了检验,结果表明二者相符较好。设计了28个模拟管束,在Re=10000~40000范围就相关结构因素对管束强化换特性的影响进行了数值模拟研究。其中,锯齿高度、锯齿宽度和锯齿扭角是锯齿螺旋翅片管特有的结构参数,本文首次对上述结构参数的影响进行了研究。此外,还通过数值模拟方法对翅片结构不同的4类钢质螺旋翅片管进行了比较。
     在紧凑式换热器换热表面综合性能比较方法的基础上,针对气流横掠管束换热的场合,提出了比较管束迎风面积、换热面积和空间体积的3种管束综合性能评价方法。本文不仅分析和比较了各结构因素对管束换热及阻力特性的影响,还比较了各结构因素对管束迎风面积、换热面积及空间体积的影响,所得结论为换热管束的结构优化提供了清晰的指导方向。
     通过本文实验与数值模拟研究,发现在相同换热量和流体输运功耗下各结构因素对管束综合性能的影响为:
     (1)在相同纵向管距下,减小横向管距可减少管束换热面积和管束体积,但同时也使管束迎风面积增大;在相同横向管距下,存在最佳纵向管距使得管束迎风面积和换热面积最小,但管束体积随纵向管距增大而增大。
     (2)随横向管距与纵向管距等比例增大,管束迎风面积减小,换热面积增大,管束体积明显增大。管距紧密布置可减少管束换热面积和管束体积,但同时迎风面积增大,换热管束外形趋于迎风面积大流道长度短的扁平状。
     (3)在相同斜向管距下随管束横向/斜向流通面积之比增大,管束迎风面积先减小后增大,管束换热面积和管束体积均趋于增大。较小的横向/斜向流通面积之比有利于减少管束换热面积和管束体积,但需注意横向/斜向流通面积之比过小会使管束迎风面积明显增大。
     (4)管束迎风面积随翅片高度增大而增大;管束换热面积随翅片高度减小而减小,但考虑到翅片与基管的成本差异,一定翅片间距下存在一最佳翅片高度使得换热管投资最小;管束体积随翅片高度增大而减小,但这种影响随翅片高度增大而逐渐减弱。随着翅片间距增大,管束迎风面积稍有增大,管束换热面积基本不变,管束体积明显增大。
     (5)随着锯齿高度增大,管束迎风面积明显增大,换热面积略微减小;在翅片管制作工艺允许的范围内,适度减小锯齿高度可进一步减小设备体积。锯齿宽度对管束迎风面积,换热管投资及管束体积均影响不大。
     (6)管束迎风面积在0°~60°范围随锯齿扭角增大而增大,在实际工程应用的锯齿扭角范围15°~30°,扭齿螺旋翅片管束的迎风面积较锯齿螺旋翅片管束增大约8%~12%;管束换热面积与管束体积在0°~30°范围均随锯齿扭角增大而减小(约5%),但在扭角30°~60°范围基本不变。
     (7)在相同的管间距和换热管结构下与连续螺旋翅片管束相比,I型锯齿螺旋翅片管、L型锯齿螺旋翅片管和扭齿螺旋翅片管的管束迎风面积分别增大约10%、23%和30%,管束换热面积分别减少约9%、6%和12%。连续螺旋翅片管、I型锯齿螺旋翅片管和扭齿螺旋翅片管在管束体积方面无明显差异,但L型锯齿螺旋翅片管的管束体积增大约18%。
Serrated fin tubes have the advantages of easy manufacturing, the larger finnedratio and the enhanced heat transfer in comparison with the conventional solid fintubes, and have been applied in various large scale heat exchangers with flue gasemissions, such as the combined cycle heat recovery steam generators (HRSGs), etc.However, the number of the published researches on the heat transfer and pressuredrop of serrated fin tube banks is very limited, and the experimental results of thedifferent researchers are mostly inconsistent on the effects of various structure factors.Such status quo hampers the efficient use and widespread application of serrated fintube. Based on the theoretically analyses of the principles of the heat transferenhancement of serrated fin tube banks, this paper performed a comprehensiveinvestigation on the thermal and hydraulic characteristics of serrated fin tube bankswith staggered layouts by means of a lot of experiments and numerical simulations.
     Twelve tube banks with different tube spacing and fin pitch were tested in a hightemperature circulating wind tunnel, resultingly obtained the respective effects oftransversal tube spacing, longitudinal tube spacing and fin pitch on the thermal andhydraulic characteristics of serrated fin tube banks in the range of Renolds numberfrom4000to30000. Based on the test data from this paper, a set of heat transfer andpressure drop correlations were presented for the related engineering design orcalculation. Then, ten testing banks were simulated using the Fluent software tovalidate the numerical methods of this paper by means of comparing the numericalresults of the heat transfer and pressure drop of tube banks, respectively, with thecorresponding experimental results. The comparison results show that the numericalresults coincided with the experimental results satisfactorily. Afterwards, twenty-eighttube banks were designed and simulated in the range of Renolds number from10000to40000, resultingly obtained the effects of almost all related structure factors on thethermal and hydraulic characteristics of serrated fin tube banks. Among which thesegment height, segment width and segment twist-angle are the particular structureparameters of serrated fin tube, this paper studied the effects of those structure factorson the thermal and hydraulic characteristics of tube banks for the first time. Moreover,this paper compared four types of helically finned tube banks by means of numericalsimulation, they were the solid fin, serrated I-foot fin, serrated L-foot fin and serratedtwist-fin tube banks, respectively.
     Based on the evaluation methodologies of the overall thermal-hydraulicperformances for the compact heat exchangers, this paper presented three evaluationmethodologies of the overall thermal-hydraulic performances for the heat exchangerswith crossflow tube banks, to compare the frontal flow areas, heat transfer areas andspatial volumes of tube banks, respectively, in a certain heat duty and transportingpower consumption of the tube outside gas. In this paper, the effects of structurefactors were compared and analyzed not only on the heat transfer and pressure drop oftube banks, but also on the overall thermal-hydraulic performances of tube banks,hence the conclusions drawn by this paper can directly guide the structureoptimization of serrated fin tube banks.
     From the experimental and numerical investigations of this paper, the effects ofvarious structure factors on the overall thermal-hydraulic performances of the serratedfin tube banks with staggered layouts were founded as follow:
     (1) In certain longitudinal tube spacing, a decrease in transversal tube spacingcould result in a decrease in the heat transfer areas and spatial volumes of tube banks,while would increase the frontal flow areas of tube banks simultaneously. In certaintransversal tube spacing, there would be an optimal longitudinal tube spacing tominimize the frontal flow areas and heat transfer areas of tube banks, while the spatialvolumes of tube banks always increased as the longitudinal tube spacing increased.
     (2) An equal propotional increase in the transversal and longitudinal tube spacingwould result in a moderate decrease and increase in the frontal flow areas and heattransfer areas of tube banks, respectively, but a significant increase in the spatialvolumes of tube banks. It means that the compact tube layouts is of benefit todecreasing the heat transfer areas and spatial volumes of tube banks, while the shapesof tube banks will tend to a pancake having a large frontal flow area and a short flowlength due to the accompanying increase in the frontal flow areas of tube banks.
     (3) In certain diagnol tube spacing, an increase in the ratios of transversal-diagnolfree flow areas of tube banks would result in an increase in the heat transfer areas andspatial volumes of tube banks, while the frontal flow areas of tube banks were firstlydecreased and then increased as the ratios of transversal-diagnol free flow areasincreased. So a small ratios of transversal-diagnol free flow areas is of benefit todecreasing the heat transfer areas and spatial volumes of tube banks, but it should beconcerned that the spatial volumes of tube banks will be increased dramatically as the ratio of transversal-diagnol free flow areas is very small.
     (4) An increase in fin height would result in an increase in the frontal flow areasand heat transfer areas of tube banks; there would be an optimal fin height tominimize the cost of finned tubes in view of the cost deffierence between fin and basetube. The spatial volumes of tube banks tended to decrease as the fin height increased,whereas the decrease extents were decreasing as the fin height increased. Thevariation of fin pitch had an insignificant effect on the frontal flow areas and heattransfer areas of tube banks, while the spatial volumes of tube banks would increasedistinctly with an increase in fin pitch.
     (5) An increase in segment height would result in an obvious increase in thefrontal flow areas and a slightly decrease in the heat transfer areas of tube banks.Within the allowable limits of the manufacturing process of serrated fin tube, themoderate decrease in segment height could make a further decrease in the spatialvolumes of tube banks. The variation of segment width had an insignificant effect onthe frontal flow areas, heat transfer areas and spatial volumes of tube banks.
     (6) In the range of segment twist-angle from0°to60°, an increase in segmenttwist-angle would result in an increase in the frontal flow areas of tube banks. In thepractical range of segment twist-angle from15°to30°, the frontal flow areas ofserrated twist-fin tube banks would be increased approximately8%~12%incomparison with the serrated fin tube banks without fin twisting. Both the heattransfer areas and spatial volumes of serrated twist-fin tube banks decreasedapproximately5%as the segment angles increased from0°to30°, and then basicallyremained unchanged as the the segment angles increased from30°to60°.
     (7) Compared with the solid fin tube bank in a certain tube spacing and thestructural parameters of finned tube, the frontal flow areas of serrated I-foot fin,serrated L-foot fin and serrated twist-fin tube banks increased approximately10%,23%and30%, respectively; and the heat transfer areas of those corresponding tubebanks decreased approximately9%,6%and12%, respectively. The spatial volumes ofthe solid fin, serrated I-foot fin and serrated twist-fin tube banks were almost same,while the spatial volumes of the serrated L-foot fin tube bank increased approximately18%relative to the solid fin tube bank.
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