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Numerical Investigation on the temperature uniformity of mill rolls and the energy efficiency during heating in the resistance furnace
IF 6.1 2区 工程技术 Q2 ENERGY & FUELS Pub Date : 2025-01-23 DOI: 10.1016/j.applthermaleng.2025.125577
Long Zhang , Mingyue Li , Yao Xiao , Yi Han , Pengfei Wang , Lu Zhang
Revealing the heat transfer characteristics and evaluating the efficiency of the forced convection resistance furnace are crucial for energy saving in the steel industry. A three-dimensional transient numerical model was established for the multi-roll simultaneous heating process, validated by experimental data from a mill roll factory. The simulation results indicated that the narrow channel formed by the adjacent three rolls induces stable boundary layers, resulting in poorer convective heat transfer and the formation of cold valleys. In contrast, hot ridges are formed on the rest surfaces due to continuous boundary layer disruption. A multidimensional multi-metric evaluation system was developed to comprehensively assess the temperature distributions of the roll barrel surfaces. Based on this, the effects of roll spacing dr, layout, and fan speed ω on roll surface temperature uniformity and process efficiency have been examined. At dr = 250 mm, the temperature non-uniformity of the three rolls decreased by 12 %, 14 %, and 22 %, respectively. When ω is increased to 2000 rpm, the overall temperature non-uniformity of the three rolls decreased by only about 14 %. Increasing fan speed improves temperature uniformity but decreases energy efficiency. A balance index of roll surface temperature uniformity and energy efficiency was proposed as a decision criterion for this trade-off. At ω = 1600 rpm, the balance index is reached maximum value, with a total temperature uniformity improvement of 5.1 % and a 7 % reduction in energy efficiency. The layout position of rolls more significantly impacts the temperature uniformity. In the optimized case, rolls 1 and 2 were placed above, thereby the temperature non-uniformity reduced by 48 % and 67 %, far exceeding the reduction caused by the increase in roll spacing and fan speed. Meanwhile, the temperature non-uniformity of roll 3 is increased by only 10 %. Overall, the total temperature uniformity of the optimized case increased by 39.7 %, while the energy efficiency and thermal efficiency decreased by only 7 % and 0.34 %, respectively.
{"title":"Numerical Investigation on the temperature uniformity of mill rolls and the energy efficiency during heating in the resistance furnace","authors":"Long Zhang ,&nbsp;Mingyue Li ,&nbsp;Yao Xiao ,&nbsp;Yi Han ,&nbsp;Pengfei Wang ,&nbsp;Lu Zhang","doi":"10.1016/j.applthermaleng.2025.125577","DOIUrl":"10.1016/j.applthermaleng.2025.125577","url":null,"abstract":"<div><div>Revealing the heat transfer characteristics and evaluating the efficiency of the forced convection resistance furnace are crucial for energy saving in the steel industry. A three-dimensional transient numerical model was established for the multi-roll simultaneous heating process, validated by experimental data from a mill roll factory. The simulation results indicated that the narrow channel formed by the adjacent three rolls induces stable boundary layers, resulting in poorer convective heat transfer and the formation of cold valleys. In contrast, hot ridges are formed on the rest surfaces due to continuous boundary layer disruption. A multidimensional multi-metric evaluation system was developed to comprehensively assess the temperature distributions of the roll barrel surfaces. Based on this, the effects of roll spacing <em>d</em><sub>r</sub>, layout, and fan speed <em>ω</em> on roll surface temperature uniformity and process efficiency have been examined. At <em>d</em><sub>r</sub> = 250 mm, the temperature non-uniformity of the three rolls decreased by 12 %, 14 %, and 22 %, respectively. When <em>ω</em> is increased to 2000 rpm, the overall temperature non-uniformity of the three rolls decreased by only about 14 %. Increasing fan speed improves temperature uniformity but decreases energy efficiency. A balance index of roll surface temperature uniformity and energy efficiency was proposed as a decision criterion for this trade-off. At <em>ω =</em> 1600 rpm, the balance index is reached maximum value, with a total temperature uniformity improvement of 5.1 % and a 7 % reduction in energy efficiency. The layout position of rolls more significantly impacts the temperature uniformity. In the optimized case, rolls 1 and 2 were placed above, thereby the temperature non-uniformity reduced by 48 % and 67 %, far exceeding the reduction caused by the increase in roll spacing and fan speed. Meanwhile, the temperature non-uniformity of roll 3 is increased by only 10 %. Overall, the total temperature uniformity of the optimized case increased by 39.7 %, while the energy efficiency and thermal efficiency decreased by only 7 % and 0.34 %, respectively.</div></div>","PeriodicalId":8201,"journal":{"name":"Applied Thermal Engineering","volume":"266 ","pages":"Article 125577"},"PeriodicalIF":6.1,"publicationDate":"2025-01-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143168991","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Optimal operation of industrial heat pumps with stratified thermal energy storage for emissions and cost reduction using day-ahead predictions
IF 6.1 2区 工程技术 Q2 ENERGY & FUELS Pub Date : 2025-01-23 DOI: 10.1016/j.applthermaleng.2025.125703
Roger Padullés , Magnus Lyck Hansen , Martin Pihl Andersen , Benjamin Zühlsdorf , Jonas Kjær Jensen , Brian Elmegaard
This paper investigates the reduction of operational costs and CO2 emissions resulting from an optimal operation of an industrial heat pump paired with a thermal energy storage (TES) in a brewery. The objective of the study is to investigate the potential benefits of load shifting using the TES and the impact of the fluctuations of electricity price, solar radiation and carbon intensity of the grid. The study employs a linear programming model to develop four distinct operation schedules for the heat pump, two aiming to minimize carbon emissions and two for operational costs. It considers both a perfect foresight scenario to illustrate the full potential and a more realistic, limited day-ahead prediction horizon. The results show that the optimal operation schedules can reduce the heat pump operating costs by up to 17.3 % and CO2 emissions by up to 15.4 %. Even under the constrained day-ahead prediction horizon, the costs could be reduced by up to 15.5 % and the emissions by up to 14.2 %. Furthermore, the study reveals the interplay between cost optimization and emission reduction since the cost-optimal scheduling would also reduce emissions and vice versa. The investigation also includes the implications of these optimal control strategies on system sizing, indicating the potential benefits of adapting to smaller storage volumes and larger heat pumps.
{"title":"Optimal operation of industrial heat pumps with stratified thermal energy storage for emissions and cost reduction using day-ahead predictions","authors":"Roger Padullés ,&nbsp;Magnus Lyck Hansen ,&nbsp;Martin Pihl Andersen ,&nbsp;Benjamin Zühlsdorf ,&nbsp;Jonas Kjær Jensen ,&nbsp;Brian Elmegaard","doi":"10.1016/j.applthermaleng.2025.125703","DOIUrl":"10.1016/j.applthermaleng.2025.125703","url":null,"abstract":"<div><div>This paper investigates the reduction of operational costs and CO<sub>2</sub> emissions resulting from an optimal operation of an industrial heat pump paired with a thermal energy storage (TES) in a brewery. The objective of the study is to investigate the potential benefits of load shifting using the TES and the impact of the fluctuations of electricity price, solar radiation and carbon intensity of the grid. The study employs a linear programming model to develop four distinct operation schedules for the heat pump, two aiming to minimize carbon emissions and two for operational costs. It considers both a perfect foresight scenario to illustrate the full potential and a more realistic, limited day-ahead prediction horizon. The results show that the optimal operation schedules can reduce the heat pump operating costs by up to 17.3 % and CO<sub>2</sub> emissions by up to 15.4 %. Even under the constrained day-ahead prediction horizon, the costs could be reduced by up to 15.5 % and the emissions by up to 14.2 %. Furthermore, the study reveals the interplay between cost optimization and emission reduction since the cost-optimal scheduling would also reduce emissions and vice versa. The investigation also includes the implications of these optimal control strategies on system sizing, indicating the potential benefits of adapting to smaller storage volumes and larger heat pumps.</div></div>","PeriodicalId":8201,"journal":{"name":"Applied Thermal Engineering","volume":"266 ","pages":"Article 125703"},"PeriodicalIF":6.1,"publicationDate":"2025-01-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143170243","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Flexible composite phase change materials with high thermal conductivity and electrical insulation properties for lithium-ion battery thermal management
IF 6.1 2区 工程技术 Q2 ENERGY & FUELS Pub Date : 2025-01-23 DOI: 10.1016/j.applthermaleng.2025.125706
Jun Ji, Yihui An, Jie Gu, Xuelai Zhang, Chaoxiang Zhang, Zhenglong Shao
Being the central component of electric cars, lithium-ion batteries release a large quantity of heat while operating. Therefore, a suitable battery thermal management system must be adopted. Conventional phase change materials have some limitations in practical applications, such as poor thermal conductivity, easy leakage, high contact thermal resistance, and lack of flexibility. These limitations place a substantial hindrance on their application in the battery thermal management systems. A novel flexible composite phase change material (FCPCM) possessing high thermal conductivity and electrical insulation was developed in the ongoing research. Here, paraffin wax (PA) was adopted as the principal PCM and styrene–butadiene–styrene block copolymer (SBS) was employed as the supporting framework to prevent leakage. This innovative approach aims to enhance the thermal performance while ensuring the integrity and reliability of the material in battery applications. Expanded graphite (EG) was incorporated to augment the thermal conductivity, while hexagonal boron nitride (H-BN) functioned as the electrically insulating reinforcing agent. The chemical characteristics, microstructure, thermal stability, and thermophysical properties of this CPCM were thoroughly assessed. The experimental outcomes show that the components of the material are only physically mixed without chemical reaction. The material exhibits excellent thermal stability, cycling performance, and thermotropic flexibility, with thermal conductivity and electrical resistivity measured at 1.13 W/(m·K) and 13.65 × 1013 Ω·m, respectively, showing its capabilities in battery thermal management. In order to investigate the heat dissipation performance of this PCM, which features high thermal conductivity and electrical insulation, within a battery thermal management system, the experimental design entails comparing the cooling outcomes of a single battery in combination with three distinct ratios of composite PCMs under various ambient temperatures and discharge rates. The CPCM containing 20 wt% H-BN was discovered to possess the optimal temperature control effect across all test conditions. The reason lies in its remarkable thermal conductivity and significant electrical resistivity, specifically in the context of higher discharge rates and ambient temperature conditions. This material can significantly reduce the maximum temperature of the battery surface.
{"title":"Flexible composite phase change materials with high thermal conductivity and electrical insulation properties for lithium-ion battery thermal management","authors":"Jun Ji,&nbsp;Yihui An,&nbsp;Jie Gu,&nbsp;Xuelai Zhang,&nbsp;Chaoxiang Zhang,&nbsp;Zhenglong Shao","doi":"10.1016/j.applthermaleng.2025.125706","DOIUrl":"10.1016/j.applthermaleng.2025.125706","url":null,"abstract":"<div><div>Being the central component of electric cars, lithium-ion batteries release a large quantity of heat while operating. Therefore, a suitable battery thermal management system must be adopted. Conventional phase change materials have some limitations in practical applications, such as poor thermal conductivity, easy leakage, high contact thermal resistance, and lack of flexibility. These limitations place a substantial hindrance on their application in the battery thermal management systems. A novel flexible composite phase change material (FCPCM) possessing high thermal conductivity and electrical insulation was developed in the ongoing research. Here, paraffin wax (PA) was adopted as the principal PCM and styrene–butadiene–styrene block copolymer (SBS) was employed as the supporting framework to prevent leakage. This innovative approach aims to enhance the thermal performance while ensuring the integrity and reliability of the material in battery applications. Expanded graphite (EG) was incorporated to augment the thermal conductivity, while hexagonal boron nitride (H-BN) functioned as the electrically insulating reinforcing agent. The chemical characteristics, microstructure, thermal stability, and thermophysical properties of this CPCM were thoroughly assessed. The experimental outcomes show that the components of the material are only physically mixed without chemical reaction. The material exhibits excellent thermal stability, cycling performance, and thermotropic flexibility, with thermal conductivity and electrical resistivity measured at 1.13 W/(m·K) and 13.65 × 10<sup>13</sup> Ω·m, respectively, showing its capabilities in battery thermal management. In order to investigate the heat dissipation performance of this PCM, which features high thermal conductivity and electrical insulation, within a battery thermal management system, the experimental design entails comparing the cooling outcomes of a single battery in combination with three distinct ratios of composite PCMs under various ambient temperatures and discharge rates. The CPCM containing 20 wt% H-BN was discovered to possess the optimal temperature control effect across all test conditions. The reason lies in its remarkable thermal conductivity and significant electrical resistivity, specifically in the context of higher discharge rates and ambient temperature conditions. This material can significantly reduce the maximum temperature of the battery surface.</div></div>","PeriodicalId":8201,"journal":{"name":"Applied Thermal Engineering","volume":"266 ","pages":"Article 125706"},"PeriodicalIF":6.1,"publicationDate":"2025-01-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143168638","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
An alternative standard thermal impedance-based approach for the dynamic modeling and characteristic analysis of the solid oxide fuel cell system
IF 6.1 2区 工程技术 Q2 ENERGY & FUELS Pub Date : 2025-01-23 DOI: 10.1016/j.applthermaleng.2025.125715
Tong Hao , Junhong Hao , Yunxi Yang , Xingce Wang , Feng Hong , Xiaoze Du
Accurately capturing the dynamic interactions between the complex heterogeneous energies inside and outside a solid oxide fuel cell (SOFC) is the key to improving energy efficiency and flexibility. This research proposes a standard thermal impedance approach to construct a novel cross-scale dynamic model for the SOFC system by considering the external thermal management subsystem and the internal coupled multi-physics processes of heat transfer, mass transfer, and electrochemical fields. The constructed model realizes the all-round cross-scale dynamic characteristics from internal process to external heat exchange by using characteristic parameters. On this basis, we simulate and validate the proposed model of the SOFC system using Matlab/Simulink platform. The results show that this approach’s feasibility and convenience provide about 67.6% improvement in computational efficiency compared to the verification model. Besides, the parameter sensitivity and dynamic response of the SOFC system is analyzed, including varying inlet temperature, load current, fuel flow rate and operating pressure. The proposed model can provide computational efficiency and high accuracy in analyzing the SOFC system behavior and enabling more precise control strategies.
{"title":"An alternative standard thermal impedance-based approach for the dynamic modeling and characteristic analysis of the solid oxide fuel cell system","authors":"Tong Hao ,&nbsp;Junhong Hao ,&nbsp;Yunxi Yang ,&nbsp;Xingce Wang ,&nbsp;Feng Hong ,&nbsp;Xiaoze Du","doi":"10.1016/j.applthermaleng.2025.125715","DOIUrl":"10.1016/j.applthermaleng.2025.125715","url":null,"abstract":"<div><div>Accurately capturing the dynamic interactions between the complex heterogeneous energies inside and outside a solid oxide fuel cell (SOFC) is the key to improving energy efficiency and flexibility. This research proposes a standard thermal impedance approach to construct a novel cross-scale dynamic model for the SOFC system by considering the external thermal management subsystem and the internal coupled multi-physics processes of heat transfer, mass transfer, and electrochemical fields. The constructed model realizes the all-round cross-scale dynamic characteristics from internal process to external heat exchange by using characteristic parameters. On this basis, we simulate and validate the proposed model of the SOFC system using Matlab/Simulink platform. The results show that this approach’s feasibility and convenience provide about 67.6% improvement in computational efficiency compared to the verification model. Besides, the parameter sensitivity and dynamic response of the SOFC system is analyzed, including varying inlet temperature, load current, fuel flow rate and operating pressure. The proposed model can provide computational efficiency and high accuracy in analyzing the SOFC system behavior and enabling more precise control strategies.</div></div>","PeriodicalId":8201,"journal":{"name":"Applied Thermal Engineering","volume":"266 ","pages":"Article 125715"},"PeriodicalIF":6.1,"publicationDate":"2025-01-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143169344","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Effect of novel methoxyl functionalized polysiloxanes on thermal conductivity and fluidity of alumina-filled silicone pastes
IF 6.1 2区 工程技术 Q2 ENERGY & FUELS Pub Date : 2025-01-23 DOI: 10.1016/j.applthermaleng.2025.125687
Shusen Wei, Lei Mao, Qi Lin, Yue Wu, Chen Jin, Shuting Zhang, Xue Hu, Hong Dong, Yanjiang Song, Zhirong Qu, Chuan Wu
Three kinds of trimethoxysilyl-functionalized siloxane oligomers with different structures were prepared through condensation and hydrosilylation reactions to increase the volume fraction of Al2O3 fillers in the polysiloxane matrix and improve their dispersibility. The surface modification effect of the oligomers with different structures on the Al2O3 particles and their influence on the thermal conductivity, thermal resistance, and cone penetration of the thermal interface materials filled with the modified Al2O3 particles were studied in detail. The thermal conductivity and cone penetration of the composite material prepared from the Al2O3 particles treated with the α-trimethylsilyloxyl-ω-trimethoxysilylethyl-terminated PDMS oligomers showed a decreasing trend with the increase of the degree of polymerization of the siloxane segment. The thermal conductivity and cone penetration of the thermal interface material filled with Al2O3 particles treated with the α, ω-bistrimethylsilyloxyl-terminated PDMS oligomers bridged by (MeO)3Si(CH2)2MeSiO segment and the methoxyl-functionalized tris(trimethylsilyloxyl-terminated polydimethylsiloxyl)silane oligomers showed a trend of first increasing and then decreasing with the increase of the length of the siloxane chain segment. The α, ω-bistrimethylsilyloxyl-terminated PDMS oligomers bridged by (MeO)3Si(CH2)2MeSiO segment showed the best modification effect on Al2O3 fillers when the degree of polymerization n = 9. It could be used to prepare a thermally conductive silicone paste with an Al2O3 particle filling volume fraction of 88.0 vol%, a thermal conductivity reached up to 9.119 W / (m· K), and a 1/4 cone penetration of about 55.0.
{"title":"Effect of novel methoxyl functionalized polysiloxanes on thermal conductivity and fluidity of alumina-filled silicone pastes","authors":"Shusen Wei,&nbsp;Lei Mao,&nbsp;Qi Lin,&nbsp;Yue Wu,&nbsp;Chen Jin,&nbsp;Shuting Zhang,&nbsp;Xue Hu,&nbsp;Hong Dong,&nbsp;Yanjiang Song,&nbsp;Zhirong Qu,&nbsp;Chuan Wu","doi":"10.1016/j.applthermaleng.2025.125687","DOIUrl":"10.1016/j.applthermaleng.2025.125687","url":null,"abstract":"<div><div>Three kinds of trimethoxysilyl-functionalized siloxane oligomers with different structures were prepared through condensation and hydrosilylation reactions to increase the volume fraction of Al<sub>2</sub>O<sub>3</sub> fillers in the polysiloxane matrix and improve their dispersibility. The surface modification effect of the oligomers with different structures on the Al<sub>2</sub>O<sub>3</sub> particles and their influence on the thermal conductivity, thermal resistance, and cone penetration of the thermal interface materials filled with the modified Al<sub>2</sub>O<sub>3</sub> particles were studied in detail. The thermal conductivity and cone penetration of the composite material prepared from the Al<sub>2</sub>O<sub>3</sub> particles treated with the <em>α</em>-trimethylsilyloxyl-<em>ω</em>-trimethoxysilylethyl-terminated PDMS oligomers showed a decreasing trend with the increase of the degree of polymerization of the siloxane segment. The thermal conductivity and cone penetration of the thermal interface material filled with Al<sub>2</sub>O<sub>3</sub> particles treated with the <em>α</em>, <em>ω</em>-bistrimethylsilyloxyl-terminated PDMS oligomers bridged by (MeO)<sub>3</sub>Si(CH<sub>2</sub>)<sub>2</sub>MeSiO segment and the methoxyl-functionalized tris(trimethylsilyloxyl-terminated polydimethylsiloxyl)silane oligomers showed a trend of first increasing and then decreasing with the increase of the length of the siloxane chain segment. The <em>α</em>, <em>ω</em>-bistrimethylsilyloxyl-terminated PDMS oligomers bridged by (MeO)<sub>3</sub>Si(CH<sub>2</sub>)<sub>2</sub>MeSiO segment showed the best modification effect on Al<sub>2</sub>O<sub>3</sub> fillers when the degree of polymerization <em>n</em> = 9. It could be used to prepare a thermally conductive silicone paste with an Al<sub>2</sub>O<sub>3</sub> particle filling volume fraction of 88.0 vol%, a thermal conductivity reached up to 9.119 W / (m· K), and a 1/4 cone penetration of about 55.0.</div></div>","PeriodicalId":8201,"journal":{"name":"Applied Thermal Engineering","volume":"266 ","pages":"Article 125687"},"PeriodicalIF":6.1,"publicationDate":"2025-01-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143170248","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Study on the effect of the porous media equivalent particulate fouling model on heat transfer performance in heat exchanger channels
IF 6.1 2区 工程技术 Q2 ENERGY & FUELS Pub Date : 2025-01-23 DOI: 10.1016/j.applthermaleng.2025.125709
Jiang Li, Zhimin Han, Wei Liu, Taozhi Wang, Hongliang Chang
With the development of modern industry, the issue of particulate fouling deposition within heat exchanger channels has become increasingly severe, significantly reducing heat transfer coefficient and potentially leading to hazards such as tube rupture and low efficiency. To investigate the impact of particulate fouling on heat transfer performance in heat exchanger channels, this paper proposes a porous media equivalent particulate fouling model, which has been experimentally validated for accuracy. The model is applied to both smooth and complex heat exchanger channels, with a comparative analysis focusing on the changes in fouling resistance and Nusselt number between the porous media equivalent particulate fouling model and the traditional particulate fouling model. Additionally, the study provides a detailed examination of the effect of fouling layer thickness on heat transfer performance in complex channels. The results indicate that the simulation results using the porous media equivalent particulate fouling model show a higher correlation with experimental data, with the average error reduced by 5.48 %. In both smooth and complex heat exchanger channels, fouling resistance increases progressively along the channel, while the Nusselt number decreases. In the complex channel, due to the influence of vortex generators, fouling resistance and Nusselt number exhibit periodic variations. When the porous media equivalent particulate fouling model is used, the obstruction effect of the fouling layer on the flow field is considered, resulting in a significant increase in fouling resistance, which in turn reduces the Nusselt number. Furthermore, in the complex channel, as particle concentration increases, the fouling layer thickness gradually increases. When the fouling layer reaches a thickness of 0.42 mm, the heat transfer efficiency decreases by 12.1 %, while flow resistance increases by 36.0 %.
{"title":"Study on the effect of the porous media equivalent particulate fouling model on heat transfer performance in heat exchanger channels","authors":"Jiang Li,&nbsp;Zhimin Han,&nbsp;Wei Liu,&nbsp;Taozhi Wang,&nbsp;Hongliang Chang","doi":"10.1016/j.applthermaleng.2025.125709","DOIUrl":"10.1016/j.applthermaleng.2025.125709","url":null,"abstract":"<div><div>With the development of modern industry, the issue of particulate fouling deposition within heat exchanger channels has become increasingly severe, significantly reducing heat transfer coefficient and potentially leading to hazards such as tube rupture and low efficiency. To investigate the impact of particulate fouling on heat transfer performance in heat exchanger channels, this paper proposes a porous media equivalent particulate fouling model, which has been experimentally validated for accuracy. The model is applied to both smooth and complex heat exchanger channels, with a comparative analysis focusing on the changes in fouling resistance and Nusselt number between the porous media equivalent particulate fouling model and the traditional particulate fouling model. Additionally, the study provides a detailed examination of the effect of fouling layer thickness on heat transfer performance in complex channels. The results indicate that the simulation results using the porous media equivalent particulate fouling model show a higher correlation with experimental data, with the average error reduced by 5.48 %. In both smooth and complex heat exchanger channels, fouling resistance increases progressively along the channel, while the Nusselt number decreases. In the complex channel, due to the influence of vortex generators, fouling resistance and Nusselt number exhibit periodic variations. When the porous media equivalent particulate fouling model is used, the obstruction effect of the fouling layer on the flow field is considered, resulting in a significant increase in fouling resistance, which in turn reduces the Nusselt number. Furthermore, in the complex channel, as particle concentration increases, the fouling layer thickness gradually increases. When the fouling layer reaches a thickness of 0.42 mm, the heat transfer efficiency decreases by 12.1 %, while flow resistance increases by 36.0 %.</div></div>","PeriodicalId":8201,"journal":{"name":"Applied Thermal Engineering","volume":"266 ","pages":"Article 125709"},"PeriodicalIF":6.1,"publicationDate":"2025-01-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143170251","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Rational design and multi-step sprayed preparation of concentration gradient CNT@WPU electrothermal coatings for the highly efficient anti-/de-icing performance
IF 6.1 2区 工程技术 Q2 ENERGY & FUELS Pub Date : 2025-01-23 DOI: 10.1016/j.applthermaleng.2025.125704
Xianghuang Zhou , Yizhou Shen , Zhen Wang , Jiawei Jiang , Senyun Liu , Weilan Liu , Yuebin Lin
Electrothermal anti-/de-icing technology is considered to be an effective means of solving the icing problem on the composite surface of multi-electric/pure-electric vehicle in the future. The electrothermal coating with carbon nanotube concentration gradient was fabricated by the multi-step spraying method, which obviously increased the rate of electric heating by inducing directional heat transfer. The coating temperature remained above 0 ℃ under various low-temperature incoming conditions, when the electric power density as low as 0.4 W/cm2. Meanwhile, the concentration gradient coating’s excellent adhesion and electrothermal stability ensured its long service life. Moreover, the surface temperature of the coating on the airfoil model increased rapidly to over 50 ℃ within 180 s at an initial electrical power density of 1.2 W/cm2, effectively preventing ice formation on the leading edge for 60 s under −15 °C, 30 m/s flow condition. Under the same conditions, 8.5 mm-thick ice on the leading edge could be swiftly removed within 22 s with initial electrical power density of 1.8 W/cm2. This strategy of conductive packing gradient design will provide new insights for advanced electrothermal anti-/de-icing material manufacturing.
{"title":"Rational design and multi-step sprayed preparation of concentration gradient CNT@WPU electrothermal coatings for the highly efficient anti-/de-icing performance","authors":"Xianghuang Zhou ,&nbsp;Yizhou Shen ,&nbsp;Zhen Wang ,&nbsp;Jiawei Jiang ,&nbsp;Senyun Liu ,&nbsp;Weilan Liu ,&nbsp;Yuebin Lin","doi":"10.1016/j.applthermaleng.2025.125704","DOIUrl":"10.1016/j.applthermaleng.2025.125704","url":null,"abstract":"<div><div>Electrothermal anti-/de-icing technology is considered to be an effective means of solving the icing problem on the composite surface of multi-electric/pure-electric vehicle in the future. The electrothermal coating with carbon nanotube concentration gradient was fabricated by the multi-step spraying method, which obviously increased the rate of electric heating by inducing directional heat transfer. The coating temperature remained above 0 ℃ under various low-temperature incoming conditions, when the electric power density as low as 0.4 W/cm<sup>2</sup>. Meanwhile, the concentration gradient coating’s excellent adhesion and electrothermal stability ensured its long service life. Moreover, the surface temperature of the coating on the airfoil model increased rapidly to over 50 ℃ within 180 s at an initial electrical power density of 1.2 W/cm<sup>2</sup>, effectively preventing ice formation on the leading edge for 60 s under −15 °C, 30 m/s flow condition. Under the same conditions, 8.5 mm-thick ice on the leading edge could be swiftly removed within 22 s with initial electrical power density of 1.8 W/cm<sup>2</sup>. This strategy of conductive packing gradient design will provide new insights for advanced electrothermal anti-/de-icing material manufacturing.</div></div>","PeriodicalId":8201,"journal":{"name":"Applied Thermal Engineering","volume":"266 ","pages":"Article 125704"},"PeriodicalIF":6.1,"publicationDate":"2025-01-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143170244","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
User engagement for thermal energy-efficient behavior in office buildings using dashboards and gamification
IF 6.1 2区 工程技术 Q2 ENERGY & FUELS Pub Date : 2025-01-23 DOI: 10.1016/j.applthermaleng.2025.125598
Eziama Ubachukwu , Jana Pick , Lea Riebesel , Paul Lieberenz , Philipp Althaus , André Xhonneux , Dirk Müller
With growing concerns about climate change and increasing energy costs, energy-efficient use of buildings offers an opportunity to decrease CO2 emissions and costs. The behavior of building occupants plays a significant role in the process of improving this efficiency both for new and existing buildings. In this work, we introduce a suite of web-based software applications that aim to encourage thermal energy-efficient occupant behavior in an office environment under the Living Lab Energy Campus (LLEC) initiative, using the campus of Forschungszentrum Jülich as a demonstration. The applications in the suite allow building occupants to visualize their energy demand and automatically control heating in the offices. Behavior change motivation is provided through the related concepts of gamification and serious games through the evaluation of behavioral energy efficiency reported as energy penalties, as wells as through real-time feedback and recommendations. An experiment was designed to test the interventions in a real-world setting, where the focus was on the setpoint temperature and ventilation habits of the occupants. The mean daily energy penalties in the ventilation intervention group was 65% lower than that of its control group (1.66 kWh vs. 4.67 kWh), with even lower penalties in the ”activated” subgroup of the intervention group (0.74 kWh). In another test building that considered both ventilation and setpoint temperature, activated offices had 56% lower daily mean energy penalties than the control (1.91 kWh vs. 4.35 kWh), while in the pilot building, the energy penalties in the activated offices was 40% less than that of its control group (1.61 kWh vs. 2.94 kWh). All these effects were statistically significant and with large effect sizes. Furthermore, year-on-year thermal energy savings of about 18% (11.8 MWh) were realized in the pilot building where occupancy-driven heating was introduced.
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引用次数: 0
A novel room temperature flexible composite phase change material based on thermoplastic polyamide elastomer and its thermal properties analysis
IF 6.1 2区 工程技术 Q2 ENERGY & FUELS Pub Date : 2025-01-23 DOI: 10.1016/j.applthermaleng.2025.125708
Furen Zhang, Haikun Tan, Xinglong Lu, Wenping Xuan
Phase change material (PCM) has the characteristics of high latent heat, wide temperature range, and good thermal stability, which makes phase change cooling an excellent passive cooling technology, and it is worth exploring in the field of battery thermal management. However, common phase change materials have low thermal conductivity, high rigidity, and easy leakage of PCM at room temperature, which greatly limits their application. In order to solve the above problems, a new flexible composite phase change material (FCPCM) was prepared by physical melting and mixing methods, using paraffin wax (PA) as the phase change substrate, polyamide thermoplastic elastomer (TPAE) as the flexible support material, hexagonal boron nature (h-BN) as the first thermal conductivity additive, and expanded graphite (EG) as the second thermal conductivity additive. The shape stability, microscopic morphology, chemical characteristics, thermal properties, flexibility characteristics, thermal shape memory characteristics, and thermal cycle stability of FCPCM were further characterized. The results show that TPAE can not only prevent the leakage of PA but also give FCPCM heat-induced flexibility so that the composite phase change material has flexible properties at room temperature. Compared with a single thermal conductivity agent, the mixed thermal conductivity of h-BN and EG can greatly improve the thermal conductivity of FCPCM. When the thermal conductivity additive content is 15 % (h-BN = 7.5 %, EG = 7.5 %), the thermal conductivity of FCPCM is 0.51 W/mK, and the thermal conductivity is 255 % of pure PA. Finally, the performance of FCPCM with different heat transfer agent content was optimized, and the selected FCPCM samples were applied in single-cell thermal management. The results show that when the battery discharge rate is 2C, 3C, and 4C, the maximum temperature of the battery is reduced by 6.09 ℃, 6.99 ℃, and 7.56 ℃, respectively, compared with pure PA.
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引用次数: 0
Performance enhancement of direct absorption parabolic trough collector using eccentric annular absorption tube and transparent insulation aerogel
IF 6.1 2区 工程技术 Q2 ENERGY & FUELS Pub Date : 2025-01-23 DOI: 10.1016/j.applthermaleng.2025.125663
Zhuo Chen, Xinyue Han, Yu Ma, Dengming Zheng
The exploitation of solar energy plays an important role in addressing both energy shortages and environmental issues. To minimize the temperature gradient and enhance the performance of direct absorption parabolic trough collectors (DAPTCs), a novel eccentric annular tube collector based on optical glass and nanofluid combined absorption is developed in this work. An optical-thermal coupled model is proposed and validated to study the performance of the eccentric annular tube collector. According to the model, a parametric investigation is performed to quantify the energy flux distribution, temperature and flow characteristics, and overall thermal collection performance of the novel system. Effects of offset distance, mass flow rate and inlet temperature on collector performance are investigated in detail. Results show that the eccentric annular tube collector with a 4 mm offset distance is recommended as the suggested design. The exergy efficiency of the proposed design under mass flow rate of 0.30 kg/s and nanofluid inlet temperature of 600 K is 30.61 %. To further minimize heat losses at high operating temperatures, transparent insulation aerogels are applied to the surface of the eccentric annular absorption tube. Compared to the evacuated eccentric annular tube collector, the collector efficiency of the modified collector with aerogel is improved by 9.27 %, and the exergy efficiency can be increased by 5.67 % under concentration ratio of 76 suns and inlet temperature of 650 K.
{"title":"Performance enhancement of direct absorption parabolic trough collector using eccentric annular absorption tube and transparent insulation aerogel","authors":"Zhuo Chen,&nbsp;Xinyue Han,&nbsp;Yu Ma,&nbsp;Dengming Zheng","doi":"10.1016/j.applthermaleng.2025.125663","DOIUrl":"10.1016/j.applthermaleng.2025.125663","url":null,"abstract":"<div><div>The exploitation of solar energy plays an important role in addressing both energy shortages and environmental issues. To minimize the temperature gradient and enhance the performance of direct absorption parabolic trough collectors (DAPTCs), a novel eccentric annular tube collector based on optical glass and nanofluid combined absorption is developed in this work. An optical-thermal coupled model is proposed and validated to study the performance of the eccentric annular tube collector. According to the model, a parametric investigation is performed to quantify the energy flux distribution, temperature and flow characteristics, and overall thermal collection performance of the novel system. Effects of offset distance, mass flow rate and inlet temperature on collector performance are investigated in detail. Results show that the eccentric annular tube collector with a 4 mm offset distance is recommended as the suggested design. The exergy efficiency of the proposed design under mass flow rate of 0.30 kg/s and nanofluid inlet temperature of 600 K is 30.61 %. To further minimize heat losses at high operating temperatures, transparent insulation aerogels are applied to the surface of the eccentric annular absorption tube. Compared to the evacuated eccentric annular tube collector, the collector efficiency of the modified collector with aerogel is improved by 9.27 %, and the exergy efficiency can be increased by 5.67 % under concentration ratio of 76 suns and inlet temperature of 650 K.</div></div>","PeriodicalId":8201,"journal":{"name":"Applied Thermal Engineering","volume":"266 ","pages":"Article 125663"},"PeriodicalIF":6.1,"publicationDate":"2025-01-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143170255","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
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Applied Thermal Engineering
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