NUMERICAL MODELING AND EXPERIMENTAL STUDY OF A NOVEL METAL-POLYMER COMPOSITE HEAT EXCHANGER FOR SENSIBLE AND LATENT THERMAL ENERGY STORAGE APPLICATIONS

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2022

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Abstract

Compact, lightweight, and low-cost heat exchangers (HXs) have the potential to improve efficiencies and save power and carbon foot print in a wide array of applications. The present study investigates an entirely additively-manufactured novel metal-polymer composite heat exchanger, enabled by an innovative and patented cross-media thermal exchange approach, which yields an effective thermal conductivity of 130 W/m-K for the heat exchanger. This record-high thermal conductivity is more than an order of magnitude higher that the previously reported thermal conductivity for polymer and polymer composite HXs. Drawing on the concept of external flow over the tube banks, the proposed HX features a staggered arrangement of fins. This class of HXs are often used for gas-to-liquid sensible cooling applications. However, they can also be designed for latent thermal energy storage applications by employing low-cost and high energy-storage-density phase change materials (PCMs) such as salt-hydrates and alike in either the hot or cold side of the HX, depending on the application. An extensive literature survey on tube banks shows that, though numerous correlations exist in the literature for flow over tube banks, these correlations usually fall outside the range for the current HX design for low-Reynolds number applications (Re<100). Furthermore, the PCM models present in the literature are either very challenging to solve analytically or are computationally expensive. Thus, the dissertation emphasizes developing computationally-efficient and robust numerical models for sensible and latent cooling applications.The numerical models compute the overall thermal and pressure-drop performance metrics based on segment-level modeling, and they integrate the performance parameters such as Euler, Nusselt numbers, or latent thermal energy with the entire HX analytically, thus significantly reducing the computational cost. For steady-state sensible thermal energy storage applications, a realistic 3D CFD-based modeling approach is used, based on the actual dimensions of the printed HXs rather than a traditional 2D CFD-based model. It also resolves the issues due to the 3D velocity field which aren’t captured in the 2D CFD models, and are particularly important for HXs utilizing narrow/micro channels. This modeling approach is used to obtain optimized HXs for case examples of 5-40 kW air-conditioning applications and 250-W electronic cooling applications for nominal operating and flow conditions. The 250-W unit is further validated experimentally and is observed to be within 17% for waterside pressure drop, 11% for airside pressure drop, and within 8% for thermal resistance when compared against experimental measurements. For transient latent thermal storage applications, an analytical-based 1D reduced order model (ROM) for segment-level modeling is developed based on 1D radial conduction inside the PCM. It is numerically validated with commercial CFD tools to within 10% except for cases where axial conduction in PCM is possible due to the high resistance of wire embedded in the PCM. The 1D ROM is used in optimizing a 1.44-MJ TES unit for peak-load building cooling applications and a 19.2-kJ HX for pulsed-power cooling applications. The 1.44-MJ unit is experimentally tested and observed to be within 17% for the melting time of complete PCM and about 8% for the freezing time of the complete PCM. Lastly, another novel and hybrid thermal energy storage design is formulated, which utilizes two different PCMs: shape memory alloys (SMAs) instead of metal wires and salt-hydrates contained inside polymer channels similar to the reference designs. Besides the thermal energy storage design, a novel methodology on Wilson plot for finned surfaces on both fluid-sides is introduced, which is first of its kind in the literature. Ongoing and future work in both these areas is also recommended in the final chapter of the thesis.

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