A Heat Spreading Model For Double-Sided Cross-Flow Manifold-Microchannel Heat Exchangers
A Heat Spreading Model For Double-Sided Cross-Flow Manifold-Microchannel Heat Exchangers
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The following assumptions and simplifications were made in
the model:
(1) Constant fluid properties and isotropic solid properties
(2) Negligible heat transfer in the manifold
(a) (3) Constant temperature Nusselt number
(4) Uniform microchannel flow distribution
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described in the next section. It is also worth noting that while iterative procedure was repeated until an energy balance was
local values of base conductance could be used, for simplicity, obtained to a tolerance of 1e-4. The sensible heat gain was
an effective value was used instead, as will be described in the computed on the cold- and hot-sides, respectively, from
ே
next section.
ͳ
Similarly, the governing equation for conservation of ܳ ൌ ݉ሶ ܥ ܶ ሺ݅ ൌ ܰ௫ ሻ െ ܶ ሺ݅ ൌ ͳሻ (8)
ܰ௬
energy in the base is given by ୀଵ
ேೣ
ͳ
߲ ଶ ܶ ߲ ଶ ܶ ܳு ൌ ݉ሶு ܥு ܶு ሺ݆ ൌ ͳሻ െ ܶு ሺ݆ ൌ ܰ௬ ሻ (9)
݇௫ ܪ ݇௬ ܪ ܰ௫
ଶ ୀଵ
߲ݔ ߲ ݕଶ (3)
ൌ
ܷ ሺܶ െ ܶ ሻ ܷு ሺܶ െ ܶு ሻ
where ܪ is the height of the base, and ݇௫ and ݇௬ are the
effective thermal conductivities in the x- and y-directions,
respectively. Due to the different geometries and orientations
of the fins, the effective thermal conductivities in the x- and y-
directions are not equal. The effective thermal conductivities
can be computed as
ݐ ܪ
݇௫ ൌ ݇ ൬ͳ ൰ (4)
ݓ ݐ ܪ
ݐு ܪு
݇௬ ൌ ݇ ൬ͳ ൰ (5)
ݓு ݐு ܪ
where ݇ is the isotropic thermal conductivity of the solid
material, ݓு and ݓ are the hot-side and cold-side
microchannel widths, ݐு and ݐ are the hot-side and cold-side
fin thicknesses, and ܪு and ܪ are the hot-side and cold-side
heights of the microchannel, respectively. These equations for
effective thermal conductivity are derived from the control
volumes given in Fig. 2(b), which assumes that all the heat is (a)
transported through the base height, ܪ . It is worth noting that
the effective conductances appearing in Eq. (3), ܷு and ܷ ,
include the effect of base conductance in the z-direction, as will
be described in the next section.
Since fluid properties were assumed to be constant, the
temperature boundary condition does not affect the
effectiveness. For simplicity, the boundary conditions were
chosen to be
ܶ ሺ݅ ൌ ͳሻ ൌ Ͳ (6)
ܶு ሺ݆ ൌ ͳሻ ൌ ͳ (7)
Eqs. (1)-(3) form a linear system of PDEs, which was
formulated and solved using a custom algorithm in Matlab.
This custom algorithm is shown in Fig. 3.
First, the base temperature was initialized as ܶ ሺݔǡ ݕሻ ൌ
ͲǤͷ. The cold-side and hot-side temperatures were then updated
by solving Eqs. (1)-(2), respectively, by using the latest values (b)
of the base temperature. The base temperature was then Fig. 2: (a) Unit-cell pattern and geometric definitions, and
(b) final model domain and sample mesh. Geometry and
updated by solving Eq. (3), and an energy balance was
mesh enlarged to show details.
computed by measuring the difference in the sensible heat loss
and gain on the hot-side and cold-side outlets, respectively. The
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It is worth noting that when the simulation converges, ܳ ൌ for the single-sided microchannel simulations are shown in Fig.
ܳ ൌ ܳு . The heat exchanger effectiveness can then be 4. It is also worth noting that the height of the base selected in
computed from the single-sided manifold-microchannel simulations was only
half the total base height, as shown in Fig. 4, since two single-
ܳ sided manifold-microchannel simulations—one for the hot-
ߝൌ (10) side and one for the cold-side—are required.
ሺ݉ሶ ܥ ǡ ݉ሶு ܥு ሻ
The governing continuity, momentum, and energy
equations were solved to a tolerance of 1e-4 for continuity and
due to the unit temperature difference applied at the base and momentum, and 1e-10 for energy. The mass-averaged fluid
inlet. temperature on the pressure outlet was then computed directly
Mesh independence was conducted by increasing the mesh in the CFD software and used to calculate the single-side
and observing the effect on heat exchanger effectiveness. A effectiveness. For a constant base temperature, the single-side
grid of 64 x 64 was found to be required to predict effectiveness effectiveness, ߝௌ , is related to the inlet, outlet, and base
to within < 1%. With the required mesh, the simulation was temperatures, ܶ , ܶ௨௧ , and ܶ௦ , respectively, by
timed to take less than 0.050 s on a 4-GHz desktop computer,
allowing one to quickly perform parametric studies and ܶ௨௧ െ ܶ
optimization. ߝௌ ൌ (11)
ܶ௦ െ ܶ
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ܷௌ ܣௌ
ߝௌ ൌ ͳ െ ൬െ ൰ (12)
݉ሶௌ ܥ
where ܣௌ is the single-side base area in the x-y plane, and ݉ሶௌ
is the single-side fluid mass flow rate at the velocity inlet. Eq.
(12) can be easily manipulated to provide an explicit solution
for ܷௌ as a function of ߝௌ . It is worth noting that since
conduction in the base is simulated in the CFD model, the
conductance computed by Eq. (12) will include the effect of
conduction in the z-direction. Further details about the single-
side microchannel simulations are provided in [12].
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effectiveness always lies between the assumption of zero heat
spreading (݇ ՜ Ͳ) and infinite heat spreading (݇ ՜ λ). In
addition, it was observed that for a low NTU values—or
equivalently, low effectiveness—the effect of heat spreading is
negligible, as both the infinite heat spreading and zero
spreading assumptions provide the same prediction. However,
as NTU exceeds ~1, the curves begin to deviate from one
another, and the heat spreading effectiveness is observed to lie
below the zero heat spreading effectiveness and above the
infinite heat spreading effectiveness. The deviation is observed
Fig. 6: Case study results and three-dimensional CFD to increase as NTU increases, and therefore, high effectiveness
validation. heat exchangers will be more severely affected by heat
spreading than low effectiveness heat exchangers.
To validate this, a full three-dimensional simulation was
performed. A diagram of the full three-dimensional model is
given in Fig. 7.
3$5$0(75,&678',(6
The effect of NTU on effectiveness was then studied for
Fig. 9: Effect of ܥ on maximum effectiveness for the case
various heat spreading assumptions. The results are displayed
of infinite heat spreading.
in Fig. 8, and indicate that regardless of NTU, the actual
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The asymptotical behavior observed can be easily the effectiveness increases. In particular, for the heat capacity
explained by considering a balanced (ܥ ൌ ͳ), high-NTU, ratio of ~0.8 given in the case study (see Table 1), the
counterflow heat exchanger. With zero heat spreading, the maximum obtainable effectiveness from Fig. 9 is 55%, which
temperature distribution in such a heat exchanger will take the is in agreement with the asymptote observed in the infinite heat
form of three parallel lines, as shown in Fig. 10(a). Thus, at the spreading result presented in Fig. 8.
cold-side inlet, the base temperature is significantly lower than Lastly, for heat exchangers with extreme heat spreading, a
at the hot-side inlet, resulting in a high effectiveness. However, “multi-pass” M2HX can been utilized. Since multi-pass heat
for infinite heat spreading, the base temperature approaches a exchangers obtain their desired effectiveness by combining
constant value, as shown in Fig. 10(b). The base temperature multiple low-effectiveness heat exchangers, heat spreading will
will always operate at the temperature at which both fluids have have a lesser effect. A sample temperature distribution for a
experienced the same difference in sensible heat. If the heat multi-pass M2HX is given in Fig. 10(c), and shows that even
capacity ratio is one, this point will be halfway between the though within each pass the base temperature is uniform, the
inlet temperatures, as shown in Fig. 10(b). Since the cold and overall effectiveness of the heat exchanger is higher than would
hot fluids cannot get hotter or colder than the base, respectively, have otherwise been possible with a single heat exchanger.
the maximum obtainable effectiveness will be 50%, which is
consistent with Fig. 9.
&21&/86,21
In conclusion, a heat spreading model for cross-flow manifold-
microchannel heat exchangers was presented in this study. The
model equations were defined, the solution algorithm
described, and the model validated. A case study was then
provided, and parametric studies performed, with the following
observations:
(1) the model presented allows heat exchanger designers to
predict the amount of heat spreading in a computationally
(a) efficient manner;
(2) for the case study, a deviation of 15% between the limiting
cases of infinite spreading and zero spreading was
observed;
(3) for the case study, the model matches the three-
dimensional CFD validation to within 1.4%;
(4) for the case of low NTU/effectiveness heat exchangers,
this model is not necessary to predict their performance, as
(b) heat spreading is not important for such heat exchangers;
(5) as NTU increases, the deviation between the heat
exchanger performance, and the limiting cases of infinite
heat spreading and zero heat spreading increases;
(6) for the limiting case of infinite heat spreading, a maximum
effectiveness exists, and is dependent of the heat capacity
ratio;
(7) to obtain a high effectiveness heat exchanger when heat
spreading is dominant, a multi-pass flow configuration can
(c) be utilized;
Fig. 10: Sample temperature distribution in a balanced,
high-NTU counterflow heat exchanger with (a) zero heat Future work includes abandoning the assumption that the
spreading (b) infinite heat spreading, and (c) infinite heat
microchannel flow distribution is uniform. If the flowrate
spreading in a multi-pass configuration.
through each channel was allowed to vary, it could be predicted
For heat capacity ratios less than one, the maximum by a separate flow distribution model, and the effect of
effectiveness is larger than 50%, as shown in Fig. 9. Since the manifold design on flow distribution and resulting heat
base must exist at the temperature at which the fluids exchanger performance could be determined, allowing the heat
experience the same change in sensible heat, the base exchanger to become even more compact.
temperature will shift towards the fluid with the higher heat
capacity ratio. This, in turn, will cause the fluid with the lower
heat capacity ratio to experience a larger temperature difference
as it is heated or cooled to the base temperature, and therefore,
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