Influence of rotational speed on effectiveness

of rotary-type heat exchanger

O. Bu yu kalaca, T. Ylmaz
Abstract This paper analyzes the effect of rotational
speed on the effectiveness of rotary-type heat exchang-
ers. Numerical, analytical and experimental studies are
carried out to investigate the inuence of rotational
speed, especially at low values. The governing partial
differential equations for the regenerator are solved nu-
merically with some assumptions. For a limiting case,
two analytical solutions are also obtained with different
assumptions. Based on the results of the numerical study
and the experiments carried out using a laboratory-made
rotary-type heat exchanger, an empirical equation that
can be used even for very small rotational speeds is
presented.
List of symbols
C heat capacity-rate for uid (Eqs. 9 and 10)
C
r
heat capacity-rate of solid (Eq. 12)
C
+
r
heat capacity-rate ratio of solid (Eq. 11)
c specic heat capacity (J/kg K)
F heat transfer surface area (m
2
)
Fo Fourier number (Eq. 6)
L width of the regenerator (m)
m
w
mass of solid matrix (kg)
_ m
f
mass ow rate of uid (kg/s)
n rotational speed (rev/s)
NTU number of transfer units (Eq. 8)
Q heat transfer rate (J)
R dimensionless period (Eq. 7)
T temperature (K)
T
+
dimensionless temperature (Eq. 3)
T
+
w;0
T
+
w
at t
+
= 0
T
+
w;1
T
+
w
at t
+
= 1
t time (s)
t
+
dimensionless time (Eq. 4)
t
0
time for one revolution of rotary regenerator (s)
U overall heat transfer coefcient (W/m
2
K)
u
f
uid velocity in the matrix (m/s)
x coordinate in the direction of uid ow (m)
x
+
dimensionless coordinate (Eq. 5)
Greek symbols
e effectiveness (Eq. 15)
u
r
correction factor for rotational speed (Eq. 31)
n a factor (Eq. 26)
Subscripts
c cold
e exit
f uid
h hot
i inlet
min minimum
max maximum
w wall
1
Introduction
A rotary-type regenerative heat exchanger consists of a
circular, porous heat transfer medium called the matrix
(rotor). The matrix rotates slowly between a hot and a
cold gas stream. Both gas streams ow continuously
through different portions of the matrix. The exchange of
energy between the two gas streams takes place by heat
transfer from the hot gas to the solid matrix and subse-
quent transfer to the cold gas. The matrix serves as a
medium to transport indirectly heat from the hot gas to
the cold gas.
The matrix can be driven by a motorgear unit with
constant or variable speed. The efciency at which the
rotary regenerator operates is dened by the speed of
rotation, which is usually arranged to respond to a signal
given by a controlled variable, such as temperature,
absolute humidity or enthalpy.
Thermal and hydraulic fundamentals are needed with
greater and greater accuracy for a correct and reliable
design, for reducing the energy waste, and for preventing
dangerous and expensive ofines (Spiga and Spiga 1987).
Transport phenomena of energy in rotary heat exchangers
were modeled by systems of partial differential equations
formulated with various simplifying assumptions (Skiepko
1989). Despite the simplicity of the differential equations
under classical assumptions, their solution has proved to
be challenging, and performance of regenerator was widely
investigated numerically with the aid of computers as well
as analytically (Baclic 1985). A quite number of attempts
were reported in the literature to solve the differential
equations (analytically or numerically) under some sim-
plifying assumptions using various techniques.
Heat and Mass Transfer 38 (2002) 441447 Springer-Verlag 2001
DOI 10.1007/s002310100277
Received on 29 January 2001 / Published online: 29 November 2001
O. Buyukalaca, T. Ylmaz (&)
Department of Mechanical Engineering
University of Cukurova
01330 Adana, Turkey
441
Skiepko (1989) investigated the effect of various
parameters on the gas and matrix temperature elds,
including and excluding thermal conduction in the matrix.
A table for the effectiveness of rotary regenerator was
presented by Romie (1990) in terms of various parameters.
Ylmaz et al. (1996) presented a calculation method for
rotary heat exchangers with various matrix geometries.
Karlsson and Holm (1943) documented the effect of
rotary mass and speed on the performance of a rotary
regenerator (Shen and Worek 1992). Kays and London
(1984) presented the effectiveness of rotary regenerators in
the form of tables and graphs as a function of number of
transfer units (NTU), (C
r
=C
min
) and (C
min
=C
max
). They
showed that when the rotational speed of the rotor is
greater than a certain value, the effectiveness of a
regenerator is constant.
Reliable and accurate data for the effect of matrix
rotational speed on the performance of a rotary regener-
ator is of great interest in connection with the increasingly
greater use of automatic control devices in high-perfor-
mance air-conditioning systems for the accurate control
of heat transfer capacity. Matrix speed is signicant not
only because of the direct inuence on the effectiveness
(thus on the heat transfer capacity) but also because of a
carry-over loss associated with the void volume of the
matrix (Kays and London 1984). This study aims to
investigate the inuence of the rotational speed on the
effectiveness of rotary type heat exchangers. The investi-
gation included experimental, analytical and numerical
methods.
2
Theoretical study
2.1
Numerical study
Despite the simplicity of the differential equations for the
transport mechanisms within the rotary regenerator under
classical assumptions, their solution has proved to be
challenging. Therefore, effectiveness of the rotary regen-
erator has been widely investigated numerically with the
aid of computers as well as analytically.
A numerical study was performed by writing a mathe-
matical model for the uid owing within the channels of
the rotary regenerator and for the wall of the channels.
Applying the rst law of thermodynamics to the unit
element of the wall and the uid, differential equations for
uid temperature and wall temperature were written with
some assumptions. Dimensionless forms of the equations
are:
1
R
oT
+
f
ot
+

oT
+
f
ox
+

Fo
f
R
o
2
T
+
f
ox
+2
NTU T
+
f
= NTU T
+
w
(for fluid) (1)
oT
+
w
ot
+
Fo
w
o
2
T
+
w
ox
+2

NTU
C
+
r
T
+
w
=
NTU
C
+
r
T
+
f
(for wall)
(2)
In these equations, the nondimensional temperature (T
+
),
time (t
+
) and length (x
+
) are dened as:
T
+
=
T T
i;c
T
i;h
T
i;c
(3)
t
+
= t=t
0
(4)
x
+
= x=L (5)
The Fourier (Fo) number and dimensionless period (R)
are given as:
Fo =
at
0
L
2
(6)
R =
u
f
t
0
L
(7)
NTU is the number of the heat transfer unit:
NTU =
UF
C
min
(8)
in which, U is the overall heat transfer coefcient and F is
the heat transfer surface area of the heat exchanger. C
min
is
the smaller of the cold (C
c
) and hot (C
h
) uid heat capacity
rates:
C
c
= m
f ;c
c
f ;c
(9)
C
h
= _ m
f ;h
c
f ;h
(10)
where _ m
f
is the mass ow rate and c
f
is the specic heat
capacity of the uid.
Heat capacity-rate ratio of the rotary regenerator C
+
r
is
dened as:
C
+
r
=
C
r
C
min
(11)
in which C
r
is the heat capacity-rate of the solid part of the
rotary regenerator:
C
r
= m
w
c
w
=t
0
= m
w
c
w
n (12)
where, m
w
and c
w
are, respectively, mass and specic heat
capacity of the solid body of the rotary heat exchanger and
n is the rotational speed, which is inverse of the time for
one revolution of rotary regenerator (t
0
).
The boundary and periodic equilibrium conditions for
differential equations (1) and (2) are given below:
(a) During the heating period:
T
+
f
x
+
= 0; t
+
( ) = 1 (13a)
(b) During the cooling period:
T
+
f
x
+
= 0; t
+
( ) = 0 (13b)
(c) During the heating and cooling periods:
oT
+
f
x
+
= 1; t
+
( )
ox
+
= 0 (13c)
(d) During the heating and cooling periods:
oT
+
w
x
+
= 0; t
+
( )
ox
+
= 0 (13d)
(e) During the heating and cooling periods:
oT
+
w
x
+
= 1; t
+
( )
ox
+
= 0 (13e)
442
(f) The uid temperature at the beginning of the heating
period is equal to the uid temperature at the end of
the cooling period:
T
+
f
x
+
; 0 ( ) = T
+
f
x
+
; 1 ( ) (13f )
(g) The wall temperature at the beginning of the heating
period is equal to the wall temperature at the end of
the cooling period:
T
+
w
x
+
; 0 ( ) = T
+
w
x
+
; 1 ( ) (13g)
Discretization equations using nite differences were ob-
tained for the coupled differential equations (Eqs. 1 and 2)
and the boundary and periodic equilibrium conditions
(Eq. 13). At the beginning of the calculations, a constant
temperature in the regenerator (a mean temperature of hot
and cold uid) is assumed. First the uid temperature and
then the wall temperature is calculated. These calculations
are carried out using a computer program written in
Fortran programming language and continued until the
temperatures do not change in each period (1; 2; 3; . . .).
From the temperatures obtained, the effectiveness of the
regenerator is calculated.
In the numerical study, in addition to the boundary
condition for the exit of the regenerator (x
+
= 1) given by
Eq. (13c), the inuence on the solution of the following
boundary conditions (Eqs. 14a and b) for uid was also
investigated and it was found that these conditions do not
inuence the results signicantly:
During the heating and cooling periods:
o
2
T
+
f
(x
+
= 1; t
+
)
ox
+2
= 0 (14a)
During the heating and cooling periods:
oT
+
f
(x
+
= 1; t
+
)
ox
+
=
o
2
T
+
f
(x
+
= 1; t
+
)
ox
+2
= 0 (14b)
Detailed information about the numerical method
employed and about the inuences of the different
boundary conditions of the uid is given by U

nal (1996).
2.2
Analytical study of limiting case
In this study, although the governing differential equations
(Eqs. 1 and 2) with the given boundary and periodic
equilibrium conditions (Eqs. 13 and 14) were solved
numerically, the same problem can also be analyzed
analytically for some limiting cases. The limiting case
analysis is of importance for verifying numerical solutions.
In the analysis given below, we assume that no cleaning
part exists, ow rates of the hot and cold uids are the
same and heating period is equal to cooling period.
The effectiveness of the rotary regenerator that
compares the actual heat transfer rate (Q) to the thermo-
dynamically-limited maximum transfer rate (Q
max
) is
dened as:
e =
Q
Q
max
(15)
If the rotational speed of the rotary regenerator
approaches zero (n 0), it can be assumed that the
matrix of the rotary regenerator is heated to the maximum
temperature of the hot uid immediately and cooled to the
cold uid temperature immediately. Therefore, the
amount of the heat transferred in half revolution would be:
Q =
m
w
2
c
w
T
h;i
T
c;i
_ _
(16)
The maximum heat that can be transferred in half revo-
lution is:
Q
max
= _ m
f
c
f
T
h;i
T
c;i
_ _
t
0
2
(17)
Using Eqs. (1517) and the denition of C
+
r
(Eq. 11) the
following expression can be written for the limiting case of
rotational speed of the rotary regenerator approaching
zero (n 0, and therefore C
+
r
0):
e = C
+
r
C
+
r
0 (18)
A more accurate equation can be derived analytically for
the limiting case of n 0, assuming constant tempera-
tures for hot and cold uids owing within the regenera-
tor. This assumption can be made for n 0, because
effectiveness approaches zero in this case.
Heating and cooling periods occur, respectively, be-
tween t
+
= 0 and t
+
= 1=2, and t
+
= 1=2 and t
+
= 1. For
the heating period (0 _ t
+
_ 1=2), heat transfer from the
uid can be neglected for the limiting case of n 0 and
therefore we can assume:
T
+
f
~ 1 (19)
Inserting this into Eq. (2), and neglecting the second de-
rivative of the T
+
w
with respect to x
+
(o
2
T
+
w
=ox
+2
), Eq. (20)
can be written for the wall temperature:
dT
+
w
dt
+
=
NTU
C
+
r
1 T
+
w
_ _
(20)
Integrating this equation between t
+
= 0 and t
+
= 1=2, the
following equation is obtained for the heating period:
1 T
+
w
1 T
+
w;0
= exp
NTU
C
+
r
t
+
_ _
(for 0 _ t
+
_ 1=2)
(21)
where T
+
w;0
is wall temperature at t
+
= 0.
A similar analysis can be performed for the cooling
period (1=2 _ t
+
_ 1). In this case, the following as-
sumption can be written for the limiting case of n 0:
T
+
f
~ 0 (22)
Inserting this into Eq. (2), and neglecting the term
o
2
T
+
w
=ox
+2
, Eq. (23) is obtained for the wall temperature:
dT
+
w
dt
+
=
NTU
C
+
r
T
+
w
(23)
Integration of Eq. (23) between t
+
= 1=2 and t
+
= 1 yields:
T
+
w
= T
+
w;1
exp
NTU
C
+
r
1 t
+
( )
_ _
(for 1=2 _ t
+
_ 1)
(24)
where, T
+
w;1
is the wall temperature at t
+
= 1.
443
T
+
w;0
is equal to T
+
w;1
since the problem is a periodic one
(t
+
= 0 and t
+
= 1 represent the same point in time).
Equations (21) and (24) must produce the same wall
temperature at t
+
= 1=2. Therefore, it follows:
T
+
w;0
= T
+
w;1
=
1
1 n
(25)
where
n = exp
NTU
2C
+
r
_ _
_ _
(26)
The heat transfer rate can be calculated from the following
equation:
Q = m
w
c
w
DT
max
T
+
w
T
+
w;0
_ _
(27)
in which T
+
w
is the mean temperature of the wall during
heating period. Equation (21) yields:
T
+
w
= 2
_
1=2
0
T
+
w
dt
+
= 1 1 T
+
w;0
_ _
2C
+
r
NTU
1
1
n
_ _
(28)
The effectiveness can be obtained from Eqs. (15), (17),
(26), (27) and (28):
e = C
+
r
n
1 n
1
2C
+
r
NTU
1
1
n
_ _ _ _
(29)
For the case of C
+
r
0, n approaches innity (n ) and
therefore, Eq. (29) simplies to Eq. (18).
3
Experimental setup
Tests were conducted using the experimental system
shown in Fig. 1, to investigate inuence of rotational speed
on the effectiveness of the rotary-type heat exchanger.
The air is drawn into the system from the room by a
blower. The ``cold air'' passes through one side of the
rotary regenerator during which it receives heat from the
solid matrix. The temperature of the pre-heated air is
then further increased by a heating coil in which hot
water is circulated. The heated air leaving the heating
coil serves as ``hot air''. The hot air is then directed to
the other side of the rotary regenerator and it rejects
heat to the solid matrix before discharged from the
system. Wire sieves were used to improve the ow at
various sections.
A rotary heat exchanger for experiments was manu-
factured in the laboratory. It was formed from many
alternate layers of at and corrugated aluminum plates of
0.35 mm thick. This construction gives a honeycomb of
passages, which can be described as ``triangular'' type, i.e.
one wall at and the other curved approximately into a
triangle, as shown in Fig. 1. The conventional manufac-
turing technique, which utilizes a pair of toothed rollers
was used to produce the corrugated strips. The resulting
ow passage geometry was approximately an equilateral
triangle (a = 3:44 mm). Adjustable seals were tted
between the casing and the rotor on both sides in order to
minimize leakage. The diameter of the rotary regenerator
is 690 mm and the width is 200 mm.
The drive system consists of a constant-speed electric
motor with a couple of reduction gears, driving the rotor
by means of a jointed V-belt. The gear system allowed us
to vary the rotational speed from 0.05 up to 7 rev/min.
During the experiments, hot and cold air ow rates,
air temperatures at upstream and downstream of both
sides of the rotary regenerator and rotational speed were
monitored continuously. K-type thermocouples with an
ice-bath cold junction were used for temperature
measurements. Nine thermocouples, distributed
uniformly, were replaced into the channel at one cross
section to be able to measure mean temperature at the
cross-section of interest. They were connected with each
other so that the output signal represents the average air
temperature at that cross-section. The cross-sections at
which temperature measurements were carried out are
shown in Fig. 1.
Flow rate of the cold and hot air was obtained from the
velocity measurements. A hot-wire anemometer was used
for velocity measurements. Velocity measurements were
performed at 70 points, distributed uniformly, for one
cross-section of the channel and then integrated to obtain
ow rate at the cross-section of interest.
A computer-controlled data acquisition system, which
consisted of a personal computer, a 16-bit analog-to-
digital converter and an interface was used for the
measurements. Detailed information about the experi-
mental setup, procedure and data processing can be
found in Atalay (1998).
3.1
Experimental parameters
In the experiments, the cold air inlet temperature was
kept constant at about 20

C while the ow rate of the

cold and hot air, rotational speed and the temperature of
the hot air were varied systematically. Analysis of the
preliminary results showed that temperature of the hot
air had no considerable effect on the effectiveness of the Fig. 1. Experimental setup
444
rotary regenerator in the range of 4050

C. Therefore,
the temperature of the hot water feeding the heating coil
was kept constant, hot air temperature varied between 40
and 50

C depending on the other parameters. Due to the

experimental arrangement used in this study, the ow
rate of the hot air is approximately equal to that of cold
air. Three different air ow rates were covered. They
were 0.576, 0.874 and 1:042 m
3
/s, which correspond to
NTU of 1.26, 1.56 and 2.32. For each ow rate 27 rota-
tional speeds were tested in the range of from a very low
value of 0.05 to 7 rev/min. The range of the rotational
speed was varied in ner increments particularly in the
low-speed region. These conditions corresponded to C
+
r
from 0.06 to 17.
4
Results and discussion
4.1
Numerical and experimental results
The effectiveness (e) of rotary regenerator was obtained by
solving numerically the differential equations (Eqs. 1 and
2) with the help of the boundary conditions for various
rotational speeds. The exact conditions of the experiments
performed were used in the numerical simulations so that
direct comparisons could be made.
The effect of the rotational speed of the rotary regen-
erator on the effectiveness is shown in Fig. 2, which shows
the variation of e with C
+
r
for three different NTU values. It
is clear from Fig. 2 that, NTU affects the effectiveness for
all C
+
r
values covered; the effectiveness is higher for cases
having large NTU values. It is also apparent from this
gure that, the effectiveness increases sharply with the
increase of rotational speed for small values of C
+
r
.
However, the rate of increase becomes smaller after about
C
+
r
1 and the change after C
+
r
5 is negligible. This
trend is similar for all three NTU values covered.
Figure 2 also shows the effectiveness values obtained
from the experiments performed. The pattern of behavior
of the effectiveness obtained from the experiments is
similar to that of numerical ones, although there are some
qualitative differences between the two. The data present
small uctuations in this case, as expected.
4.2
Kays and London data
Kays and London (1984) compiled the numerical results
for the effectiveness of rotary regenerators from Lamb-
ertson (1958) and Bahnke and Howard (1964). They
provided the results in the form of tables and graphs for
some values of C
+
, C
+
r
and NTU. The effectiveness values
that were obtained by interpolation from the tables, for the
parameters covered in the experiments are shown in
Fig. 3. Kays and London presented no effectiveness values
for small rotational speeds (therefore C
+
r
), the minimum
value of C
+
r
was 1. Therefore, the curve goes only down to
C
+
r
= 1 in Fig. 3.
The data again exhibit a similar pattern seen in those
obtained from our numerical and experimental study.
4.3
Comparison of the results
The results are normalised by dividing both effectiveness
and C
+
r
with the corresponding effectiveness values for
large C
+
r
(C
+
r
) values (e
0
) in order to compare the
results obtained from the numerical, and the experimental
study. Figure 4 shows the normalised numerical effec-
tiveness values. As can be seen from the gure, the
normalised effectiveness values for three different NTU
values overlap each other. Similar result can also be seen
in the case of the experimental results which are also
shown in Fig. 4. In this case, however, there are small
discrepancies between the results, especially in the region
of 2 _ (C
+
r
=e
0
) _ 6 due to experimental uncertainties.
The comparison of the numerical and the experimental
effectiveness values is made on the basis of the normalised
values in Fig. 5. From the gure, a good agreement
between the results is evident. A least square t to all the
points (with a standard error of the estimate of 0.054 and a
correlation coefcient of 0.99) yields:
Fig. 2. Variation with C
+
r
of the effectiveness obtained from the
experimental and numerical studies
Fig. 3. Variation with C
+
r
of the effectiveness obtained from the
Kays and London (1984) data
445
e =
C
+
r
1 3 C
+
r
=e
0
_ _
2
C
+
r
=e
0
_ _
4
_ _
1=4
(30)
in which e
0
can be calculated using the method given by
Ylmaz and Buyukalaca (unpublished data). Equation (30)
is shown in Fig. 5.
Equation (30) and the data obtained from Kays and
London are compared in Fig. 6. Equation (30) is in rea-
sonably good agreement with the data of Kays and London
for high C
+
r
=e
0
values [(C
+
r
=e
0
) > 6[. However, for smaller
values of C
+
r
=e
0
, Kays and London data lie considerably
above Eq. (30). From this gure it is clear that Kays and
London data are valid only for high rotational speeds and
they cannot predict correctly the inuence of rotational
speed for low values of rotational speeds. It should be
stressed that Kays and London data do not contain values
for small rotational speeds at all. The minimum C
+
r
=e
0
value is about 1.35.
Figure 6 also shows Eq. (18) that was obtained for the
limiting case of rotational speed of the rotary regenerator
approaching zero (n 0, and therefore C
+
r
0). Equa-
tion (30) approaches the limiting case equation (Eq. 18)
for C
+
r
0.
Kays and London suggested the following empirical
equation to take into account of the rotational speed:
e = e
o
u
r
(31)
in which, u
r
is a correction factor for rotational speed and
it depends on the heat capacity-rate ratio of the rotary
regenerator (C
+
r
):
u
r
= 1
1
9C
+1:93
r
(32)
This equation is compared with Eq. (30) in Fig. 7. As can
be seen from this gure, the curves produced by Eq. (32)
for 3 different NTU values do not overlap each other.
Another striking point is that, this equation does not
produce zero for C
+
r
= 0, the correction factor is zero at
C
+
r
= 0:32. These make it clear that Eq. (32) cannot be
used to estimate the inuence of rotational speed on
Fig. 5. Comparison of the normalized numerical and experi-
mental results
Fig. 7. Correction factor u
r
suggested by Kays and London
(1984)
Fig. 4. Variation with C
+
r
=e
0
of e=e
0
obtained from the numerical
and experimental studies
Fig. 6. Comparison of the present results with the data of Kays
and London (1984)
446
effectiveness of a rotary regenerator for low rotational
speeds.
A similar empirical correction factor was given by
Worse-Schmidt (1991):
u
r
= 1
0:114 1 e
(NTU)
_
C
+0:44
C
+1:93
r
(33)
which is valid for 0:2 _ NTU _ 5; 0:5 _ C
+
_ 1 and
C
+
r
> 1. The results produced by this equation are very
close to that of Eq. (32) (Fig. 8). However, difference
between the values for 3 different NTUs is not as large as
seen in the case of Eq. (32).
Figure 9 compares the results of the numerical study,
Eqs. (18) and (29). As can be seen from the gure, for the
limiting case of very small rotational speeds (therefore C
+
r
),
Eq. (29) is more accurate than Eq. (18) in the region of
C
+
r
< 0:15. A good agreement between all the data is
evident for C
+
r
< 0:05.
5
Conclusion
Numerical solutions of the governing differential equa-
tions of the regenerator were obtained for various values of
C
+
r
and NTU. Two different analytical solutions of the
governing differential equations were also obtained for the
case of rotational speed of the rotary regenerator
approaching zero (n 0) and the results (Eqs. 18 and 29)
were compared with the numerically-obtained values. It
was seen that numerically-obtained effectiveness values
approach the limiting case equations in the region of small
C
+
r
. The correction factors suggested by Kays and London
(1984) and Worse-Schmidt (1991) cannot be used at low
rotational speeds. A correlation equation (Eq. 30) was
obtained using the results obtained from the numerical
and the experimental study that was carried out utilizing a
laboratory-made rotary regenerator. Equation (30) can be
used even for very low rotational speeds.
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Fig. 9. Limiting case
Fig. 8. Correction factor u
r
suggested by Worse-Schmidt (1991)
447