Numerical Investigation of Heat Transfer and Fluid Flow

Characteristics in Solar Air Heater Duct with

Chamfered Ribs Mounted on Absorber Plate

Shyam S. Gupta, Bhupendra K. Gandhi and Krishna M. Singh
Department of Mechanical and Industrial Engineering, Indian Institute of Technology, Roorkee,
India
ABSTRACT

Computational analysis of heat transfer and fluid flow characteristics of artificial roughness in
the form of chamfered ribs on a broad, heated wall of a rectangular duct has been carried out in
the present work for turbulent flow in Reynolds number range 300020000 relevant in solar air
heater. Two turbulence models, k- and k-, are selected for comparing the predictions of
different turbulence models with experimental results available in the literature. The analysis is
done in 3D for coarse, fine and very fine mesh in FLUENT and total number of cells analyzed
for very fine mesh is 20, 87,228. Computational results for roughened duct have been compared
with the results for the smooth duct. A significant enhancement of heat transfer is observed in
comparison to that for a smooth duct. The predictions by k- turbulence model agree reasonably
well with the experimental results reported in literature in comparison to those by k- turbulence
model.

INTRODUCTION

One of the most effective means of heat transfer enhancement is making use of an artificial
roughness element on the heat-transferring surface. Artificial roughness has been extensively
used in solar air heaters, nuclear reactors, heat exchangers, gas turbine and blade cooling
channels. An artificial roughness in the form of ribs or wires of various geometrical shapes on
the heat transfer surface acts as projections which mainly create turbulence near the wall or
break the laminar sub-layer, and thus enhance the heat transfer coefficient between the absorber
plate and air. This results in improved thermal performance of solar air heater. However, the use
of these artificial roughness elements also results in considerably large increase in friction factor,
and hence in the pumping power. There are number of experimental studies [1-6] in which
various investigators have shown that the geometry of the roughness (roughness shape, pitch,
height, chamfered angle etc.) has a marked influence on the heat transfer and friction
characteristics of the surface. The present study is concerned with the transitionally rough flow
regime (5 < e
+
<70). Karwaa et al. [1] presented experimental investigation for the generation of
friction and heat transfer data pertinent to heating of air in a rectangular duct with integral
rectangular and chamfered repeated rib roughness on one broad wall subject to uniform heat-
flux. Range of roughness and flow parameters covered in their study were aspect ratios of the
rectangular duct (W/H) 4.8-12, Reynolds numbers (Re) 3000-20000, relative roughness heights
(e/D
h
) 0.014-0.032, relative roughness pitch (p/e) 4.5-8.5, and rib chamfer angles () -15 to
+18. They found highest heat transfer and also the highest friction factor for 15 chamfered ribs.
Ebrahim Momin et al. [6] carried out an experimental investigation of the effect of geometrical
parameters of V-shaped ribs on heat transfer and fluid flow characteristics of rectangular duct of
solar air heater with absorber plate having V-shaped ribs on its underside. The thermo-hydraulic
performance was reported maximum with an angle of attack of 60. Jia et al. [4] dealt with an
investigation of the heat and fluid flow in 45 V-shaped ribbed ducts, arranged both inline and
staggered with the Reynolds number ranging from 15,000 to 32,000 and rib depth to duct height
ratio (e/D
h
) 0.0625. Bonhoff et al. [7] investigated the flow characteristics within coolant channels
experimentally and numerically to assess the current capability of Navier-Stokes codes to predict
flow and heat transfer in coolant passages. For the calculations, FLUENT was used. Three
different turbulence models standard k- model with wall functions, differential-Reynolds stress
model with wall functions and standard k- turbulence model with a two-layer wall model were
used. Bredberg and Davidson [8] presented numerical predictions of flow and heat transfer in a
stationary two-dimensional rib roughened passage using low Reynolds number turbulent models.
The turbulence models used a set of k- turbulence models and an explicit algebraic Reynolds
stress model (EARSM). The predicted flow field showed a good agreement with experimental
results. Bredberg et al. [9] have used a new method with k- turbulence model, where the
turbulent kinetic energy equation at the first interior node is solved rather than prescribed. This is
particularly important in re-circulatory flows since the law of wall is applicable only for
equilibrium flow. The predicted heat transfer results with this new model were found comparable
with experimental results. Youn et al. [10] carried out numerical simulations of incompressible
turbulent flow through rectangular duct with one side rib roughness to determine the pressure
drop using PHOENICS commercial software package. Acharya et al. [11] have studied the flow
in the upstream and downstream recirculation region of a separated duct flow past a wall
mounted two dimensional ribs and evaluated the ability of the nonlinear k- model to predict the
flow behavior. Ooi et al. [12] carried out the simulation of the flow and heat transfer in rib
roughened ducts and cavities using the v
2
f, SA and two-layer k- turbulence models. Yang et
al. [13] carried out the numerical calculation of heat transfer and fluid flow characteristics in
rectangular ducts with slit and solid ribs mounted on one wall. The k- turbulence model with
wall function was used as a reference.
The main aim of the present analysis is to numerically investigate the flow and heat
transfer characteristics of a chamfered rib (15
0
) roughened solar air heater duct with only one
principal (broad) wall subjected to uniform heat. The ribs are provided only on the heated wall
and the other three walls are smooth and insulated. The range of parameters is given below:
Rib height, e = 1.68mm Rib width, w = 1.65mm
Pitch, p = 7.69 Chamfer angle, = 15
Depth of duct, H = 148.8mm Width of duct,W = 31.7mm
Relative roughness pitch, p/e = 4.58 Length of Plate, L = 1.64m
Relative roughness height, e/D
h
= 0.0321 Channel aspect ratio, W/H = 4.69
Test length to hydraulic diameter ratio of duct, L/D
h
= 31.36

MATHEMATICAL FORMULATION
Physical model used in the present study is shown in Figure 1.The test section consists of a long
rectangular duct integrated with an absorber plate of 6mm (having chamfered ribs) at the top of the
duct wall. Three smooth wall of the duct are insulated and a constant heat flux is given on the top
wall of the absorber plate. Basically, there are 212 ribs integrated with absorber plate.

Figure 1. Physical model
Simulation involves the analysis of 3-D heat transfer and fluid flow characteristics of
turbulent flow in rectangular duct with 15
0
chamfered ribs mounted on one wall. The governing
equations to be considered are the time-averaged continuity, momentum, and energy equations.
Two eddy viscosity model standard k- and standard k- are used to account for the effect of
turbulence. The selection of model is carried out by comparing the predictions by different
models with experimental results available in the literature. The flow is assumed to be steady,
incompressible and three-dimensional. In addition, the thermo physical properties of the fluid are
assumed to be constant. The 3-D governing equations for steady turbulent flow based on the
Reynolds decomposition for the flow variables, i.e.
i i i
u u u' = + , p p p' = + and T T T' = +
where x and x' denote the mean and fluctuating component of a variable x, are given below.
The continuity equation is given by
0
i
i
u
x
c
=
c
(1)
Using Boussinesq assumption that relates the Reynolds stresses to eddy viscosity
t
by
j
i
i j t
j i
u
u
u u
x x

| | c
c
' ' = +
|
|
c c
\ .
(2)
the momentum equations are given as
( )
j
i i
j t
j i j j i
u
u u p
u
x x x x x

( | | c
c c c c
= + + + ( |
|
c c c c c
(
\ .
(3)
The energy equation is given by
Pr Pr
t
j
j j t j
T T
u
x x x

(
| | c c c
= +
( |
c c c
( \ .

(4)
where Pr
t
denotes the turbulent (eddy) Prandtl number.

NUMERICAL COMPUTATION
The solution domain shown in Figure 1 has been selected to match the experimental model given
by Karwa et al. [1]. The simulations have been done for eight sets of mass flow rate (0.00493-
0.02837 kg/s) and heat flux (290.0-947.3 W/m
2
) for 15
0
chamfered rib geometry. The inlet
velocity, atmospheric pressure as outlet pressure, and no-slip wall boundary conditions are taken
for the purpose of analysis. A uniform heat flux is given at upper wall of absorber plate, keeping
all other walls smooth and insulated. For the generation of grid in the computational domain,
hexahedral elements with mapping and sub-map scheme have been used. A grid system with a
large concentration of nodes in the regions of steep gradients, such as those close to the walls
and around the rib, was employed.
As per the guidelines for enhanced-wall treatment, the mesh near the wall should be fine
enough to resolve the laminar sub layer or nearest nodes from the wall are located such that y
+
=
1. However, a higher y
+
is acceptable as long as it is well inside the viscous sub-layer (y
+
< 4 to
5). A 3D analysis is carried out with 20, 87,228 cells in FLUENT and compared with
experimental results. Segregated solution method is used to discretize and solve the governing
equations for continuity, momentum, energy and other scalars such as turbulence. The governing
equations are solved sequentially by control-volume-based technique. For discretization of
convective terms first order upwind scheme is used and SIMPLE algorithm is used to compute
the flow field by pressure velocity coupling method. The solution is considered to be converged
when the normalized residual is less than a prescribed value of 10e-3, except the residual for
energy equation for which the tolerance is kept 10e-6.

RESULTS AND DISCUSSIONS
Using 3-D visualization features in Fluent, we studied the velocity and temperature fields in the
duct with focus on the re-attachment and separation at the roughened wall, temperature
variations along the duct. We summarize here some of the salient features as 2-D line graphs.
Plate temperature distribution is given in Figure 2 which indicates that at the inlet the plate
temperature is less and it increases rapidly up to some distance around 300mm (6 times hydraulic
diameter) from the inlet because high heat transfer in the thermally developing region compared
to the developed region. In the thermally developed region, the temperature increases gradually
and at the outlet, drop in plate temperature appears due to the end effect. Fluid bulk temperature
distribution along the test section is shown in Figure 3, which seems to be a straight line which
can be found by joining points of inlet bulk fluid temperature and outlet bulk temperature.



Figure 2. Plate temperature distribution along the duct
Bulk temp along the duct
0
10
20
30
40
50
60
70
0 500 1000 1500 2000
Duct length (mm)
B
u
l
k

t
e
m
p

o
C
Bulk temp along
the duct

Figure 3. Bulk fluid temperature distribution along the duct
0
10
20
30
40
50
60
0 10000 20000
Reynold no
B
u
l
k

o
u
t
l
e
t

t
e
m
p

o
C
experimental
standard k-w
standard k-e

Figure 4. Variation of Bulk outlet temperature with Reynolds Number
Validation of computational results is done with smooth duct results as well as
experimental results reported by Karwaa et al. [1]. Variation of bulk outlet temperature with
Reynolds number is shown in Figure 4 for experimental, standard k- and standard k- model
results. It indicates that the bulk outlet temperature firstly increases with increase in Reynolds
number and achieves maximum value at Reynolds number value 5156 and then continuously
decreases with increase in Reynolds number. The computational results of standard k- and
standard k- are having maximum of 1
o
C difference with experimental results i.e. almost having
same value.
Figure 5 shows the variation of Nusselt number with Re for smooth duct as well as
experimental and computational results. In all cases, Nu increases with increase of Re. The rate
of increase of Nu with the Re is substantially higher in rough duct in comparison to that of
smooth duct due to the enhancement of heat transfer by artificial ribs. The standard k- and
standard k- computational results over-predict the Nu up to Re of 5000 but after that those
under-predict for higher range of Reynolds number. The standard k- model results are better
than those of standard k- model when compared with experimental results. The absolute average
deviation in case of standard k- model is found to be 20.1%, whereas in case of standard k-
model, it is 30.7%.

Figure 6 shows the comparison among the smooth duct, experimental and computational
results for friction factor variation with Reynolds number. The modified Blasius equation has
been used for finding the results for smooth duct. In comparison to the smooth duct, the higher
value of friction factor is found for all results, whether these are experimental, correlation or
computational results. Artificial roughness increases the pressure loss, and thus increases the
friction factor. The predictions shown by both standard k- and standard k- do not have a good
agreement and under-predict as compared to experimental results. But the prediction of standard
k- model agrees with Cole-Brook and White correlation. However, results with the standard k-
model do not show good agreement with the same correlation. The average deviation for the
results with the standard k- model is found to be 23.43 % from the experimental data and only
7.53% from the correlation. Whereas, the average deviation is found to be 26.5% from
experimental and 17.62% from the correlation for standard k- model.
0
10
20
30
40
50
60
70
80
90
100
0 5000 10000 15000 20000
Reynold no
N
u
s
s
e
l
t

n
o
Experimental
standardk-w
standard k-e
Smooth Duct-Dittus-
Boelter

Figure 5. Variation of Nusselt Number with Reynolds Number
0
0.005
0.01
0.015
0.02
0.025
0.03
0 5000 10000 15000 20000
Reynold no
F
r
i
c
t
i
o
n

f
a
c
t
o
r
Experimental
standard k-w
standard k-e
Cool brook-White
Eq.
Smooth duct-
Modified Blasius

Figure 6. Variation of Friction factor with Reynolds number
CONCLUSIONS
The 3D numerical analysis has been carried out to investigate the effect of artificial chamfered rib
roughness on the heat transfer and flow characteristics of absorber plate of a solar air heater duct
of aspect ratio 4.57 in the Re number range of 3000-20000.the roughened absorber plate is
subjected to constant heat flux while the other three wall of the duct were smooth and insulated.
Two turbulence models, standard k- and standard k-, have been used in the analysis through
Fluent. The prediction by standard k- turbulence model agrees reasonably well with the
experimental results reported in the literature in comparison to that by standard k- turbulence
model. The standard k- result for Nusselt number has 20.1% absolute average deviation with
the experimental results. The standard k- results for friction factor have 23.43% absolute
average deviation with the experimental results. Whereas, the same results of friction factor have
been compared with Cool-Brooke and White equation, which shows an absolute average
deviation 7.53%. It is therefore concluded that the standard k- turbulence model is reasonably
good and reliable model to estimate the effect of surface roughness on heat transfer and fluid flow
characteristics of roughened ducts.

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