摘要
工业生产中所用的冷却塔因冷却水与空气直接接触,水质容易受污染,蒸发式冷却器因其环保、节能、洁净等优点,广泛应用于化工、冶金等行业。在目前蒸发式冷却器试验研究、数值计算和CFD模拟的基础上,本文将试验研究、数值计算和CFD模拟相结合,研究了蒸发式冷却器的传热传质过程,分析了其热力性能。主要研究工作和结论如下：
(1)搭建了蒸发式冷却器的试验测试平台,测试不同工况下的热力性能,分析了喷淋水流量、风速和空气湿球温度对管内冷却水出口温度、喷淋水温度、空气出口焓值和传热系数等的影响,当喷淋水流量达到最小喷淋密度时,换热量随喷淋水流量的增加几乎不变,拟合得到了喷淋水膜对流传热系数和水膜对空气传质系数经验公式。
(2)从传热传质基本原理出发,分别针对Poppe和Merkel假设,构建了蒸发式冷却器的数学模型,分别建立了对Poppe法和Merkel法的一维和二维Matlab计算流程和相应计算程序,并与椭圆管型蒸发式冷却器的试验数据对比,一维和二维模型计算所得的管内冷却水出口温度几乎一致,结果表明采用一维模型即可准确计算预测其热力性能；Merkel法与Poppe法所得的沿盘管高度方向的热流密度分布比值在1.01-1.06之间,致性较好；Poppe法预测的出口空气温度和含湿量更接近试验测试值,而且稳定性更好。建立了基于Poppe法的空气处于过饱和情况下的分段计算模型,计算前先判断微元单元空气是否过饱和然后选择相应的微分方程求解,理论分析预测了空气饱和度对换热量、管内冷却水出口温度,空气出口干球温度、含湿量分布及焓值分布的影响,对于过饱和的情况,假设为非饱和情况对于准确预测管内冷却水出口温度和设备换热量是非常有效的；但如果空气过饱和,采用非饱和的Poppe法假设无法准确预测出口空气的干球温度和含湿量；过饱和情况容易发生在空气干球温度较低时。
(3)采用CFD软件——ANSYS FLUENT中的Species transport without reactions模拟分析蒸发式冷却器的热力性能和流场分布,结果表明：标准k-ε模型和非平衡壁面函数是预测圆管和椭圆管型蒸发式冷却器热力性能的最佳组合。将数学分析模型与FLUENT模拟相结合来预测蒸发式冷却器的热力性能,对比了试验、数学分析模型和FLUENT所得的数据,验证了FLUENT模拟的可行性；同时对比数学分析模型与FLUENT模拟所得的含湿量和温度分布。
(4)采用FLUENT模拟分析了旁路流、管型和椭圆管排列形式对蒸发式冷却器性能的影响。随着旁路宽度的增加,旁路面积占最小流通面积的比例增加,流经旁路的空气占总空气流量的百分比增加,通过这些旁路的空气,没有充分参与传热传质,导致出口空气焓值下降,设备换热性能降低,影响其使用经济性和高效利用性。因此,在蒸发式冷却器的安装过程中,满足管束与箱体最小装配间隙时,应尽量避免过大的间隙；对比分析了圆管和3种不同长短轴比的椭圆管的热力性能,包括出口空气焓值、传质柯尔本因子、旁路流所占比例以及局部的流线和含湿量等值线,椭圆管的传质柯尔本因子高于圆管；通过对椭圆管排列形式的模拟,发现：随着管束与空气竖直方向流向夹角的增大,流线弯曲程度增加,湍流程度增大,传质过程得到强化。
In industry, due to the fact that the cooling water in cooling towers directly contacts with air, cooling water can easily be polluted. Evaporative coolers because of its environmentally friendly and energy-savings, are widely used in chemical, metallurgy, etc. Based on the experimental investigation, computational analysis and CFD simulation, the heat and mass transfer and thermal performance of the evaporative coolers are presented as follows:
(1) The experimental test platform was set up and the thermal performance characteristics of the oval-tube and twisted-tube evaporative coolers were studied. The impact of deluge water flow rate, air velocity and air wet bulb temperature on the process water outlet temperature, deluge water temperature, air outlet enthalpy and heat transfer coefficient were analyzed. The deluge water flow rate had little impact on the heat transfer rate when it reached the minimum flow rate. From the experimental results, correlations for the water film heat transfer coefficient and air-water mass transfer coefficient were developed.
(2) By employing these assumptions and following an approach similar to Poppe and Merkel, analytical models of the evaporative cooler were derived from basic principles. Flowchart of the calculating process were showed as one and two-dimensional models. Compared with the experimental data, the predicted outlet process water temperatures showed little difference between the one and two-dimensional models, thus one-dimensional model was proposed. The distribution of heat flux along the evaporative cooler by Poppe and Merkel methods compared well with each other and was between1.01and1.06. The predicted outlet air temperature and humidity ratio by Poppe method were closer to the experimental data. Analytical model was adopted to investigate the thermal performance under supersaturated condition based on Poppe method and solved by a sectional method. Under the supersaturated condition, whether the air was supersaturated or not was determined by the program, then the program automatically selected the corresponding governing equations. The effect of degree of saturation of inlet air on the heat transfer rate and process-water outlet temperature was presented, and little difference was found between the unsaturated and supersaturated conditions if the outlet air was supersaturated. The air temperature, humidity ratio and enthalpy distributions under both unsaturated and supersaturated conditions could be predicted with the analytical model and the differences between the two conditions were also presented. The assumption that the air was unsaturated was a very useful assumption to predict the total heat transfer rate and outlet process-water temperature of the evaporative coolers if the actual air was supersaturated. Supersaturation was likely to occur at low inlet air temperature. The predicted air temperatures and humidity ratio were not very close to the two conditions if the outlet air was supersaturated.
(3) The thermal and hydraulic performance of plain tube and oval tube evaporative coolers were investigated numerically. Computational fluid dynamics (CFD), ANSYS FLUENT12.1, was implemented for the numerical solution. Species transport without reactions was adopted to simulate the mass transfer from the air-deluge water interface to the air. Different turbulence models and near-wall treatments were used to assess which model fit the data better. The mass transfer Colburn factor jm, and friction factor/were presented and compared with experimental data. The Standard k-ε model with non-equibibrium wall functions was the most suitable combination for the prediction. The proposed FLUENT model was also applied to predict the mass transfer coefficient of other evaporative coolers and compared well with experimental data. The comparison between computational analysis and FLUENT simulation showed an acceptable agreement with each other.
(4) The bypass flow, tube type and tube layout pattern were investigated numerically. The fraction of the bypass to total flow rate increased with the increasing of the bypass width. Thus, the fraction of the air crossing the tube bundle decreased, which resulted in the lower of the outlet air enthalpy and less heat transfer rate. It was proposed to avoid leakage if the minimum requirement of assembling was reached. Different tube types (plain and oval tube with three different axial ratio) were adopted to analyze thermal performance, which included the out air enthalpy, mass transfer Colburn factor, fraction of bypass. The results showed mass transfer Colburn factor for the oval tube was higher than that for the plain tube. The simulation of the tube layout pattern concluded the larger the tube layout angle, the higher the turbulent intensity and mass transfer.
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