CFD Analysis of CO2 Natural Circulation Loop
CFD Analysis of CO2 Natural Circulation Loop
CFD analysis of a CO2 based natural circulation loop with end heat exchangers
Ajay Kumar Yadav, M. Ram Gopal*, Souvik Bhattacharyya
Department of Mechanical Engineering, Indian Institute of Technology Kharagpur, Kharagpur 721302, India
a r t i c l e i n f o a b s t r a c t
Article history: 3-D steady flow simulation of a CO2 based, single-phase (subcritical and supercritical) rectangular natural
Received 4 August 2011 circulation loop (NCL) with end heat exchangers is presented. Viscous dissipation in fluid and axial
Accepted 18 October 2011 conduction in fluid as well as in solid wall are considered. Results are obtained for various inlet
Available online 3 November 2011
temperatures of water in the hot heat exchanger, for a fixed inlet temperature of cooling water in the cold
heat exchanger. Effect of loop operating pressure (60e100 bar) on system performance is also investi-
Keywords:
gated. Results show that due to the presence of bends and strong buoyancy effects near pseudo-critical
Natural circulation loop
zone, local velocity and temperature vary in all three dimensions. It is noticed that at a given loop
CFD
Turbulent flow
pressure, the variation of heat transfer rate with loop fluid temperature changes sign in the vicinity of
Supercritical carbon dioxide pseudo-critical region. Steady-state Reynolds number and heat transfer coefficients obtained through the
Heat transfer CFD analysis are compared with those calculated using available correlations. Although qualitative trends
match, quantitative differences exist that may be attributed to difference in configuration. Additionally,
new correlations are proposed for Re in terms of modified Gr, and Nu in terms of Re and Pr which are
expected to be useful in the design and analysis of NCLs with end heat exchangers.
Ó 2011 Elsevier Ltd. All rights reserved.
1. Introduction Zhang et al. [11] and Chen et al. [12] reported studies on the effects
of heat transfer and the instabilities of supercritical CO2 flow in
Natural circulation loop (NCL) based secondary fluid systems a 2-D NCL at a fixed operating pressure of 90 bar operating over
are simple and reliable due to the absence of any moving a large heat source temperature range. However, their analysis
components such as pumps. While water based NCLs are widely considered the case of isothermal heat source and heat sink only.
used in applications such as solar collectors, nuclear reactors, etc, There are many practical applications in which end heat
a wide variety of brines is used for low temperature applications. exchangers are used for heat source and sink (e.g. refrigeration and
In recent years, a growing popularity of carbon dioxide as the air-conditioning systems, solar collectors, solar power plants). In
secondary fluid has been witnessed in both forced as well as in studies on estimation of in-tube cooling heat transfer coefficient
natural circulation loops. This may be attributed to the favourable for turbulent forced convection of supercritical CO2, correlations
thermo-physical properties of CO2 in addition to its environment developed by Pitla et al. [13] and Du et al. [14] are usually
friendliness. Studies show that for low temperature refrigeration employed. However, Du et al. [14] suggested the use of 3-D model
and air-conditioning applications, CO2 based NCLs are very to study the behaviour of supercritical CO2 near the pseudo-critical
compact in comparison to other conventional working fluids [1] point. Studies on heat transfer coefficient for supercritical CO2
and have been proposed for various heat transfer application based NCLs are scarce in literature. In addition, to account for the
such as new generation nuclear reactors [2], in chemical extraction strong buoyancy effects (local) near pseudo-critical zone, and the
[3,4], cryogenic refrigeration [5], heat pump [6], electronic cooling effect of bends in pipe etc., it becomes essential to consider
systems [7], in geothermal applications [8,9], etc. However, a three-dimensional model for greater accuracy. However, inves-
detailed modelling and analyses of CO2 based NCLs are relatively tigations employing 3-D models of CO2 based NCLs with end heat
sparse in the literature. Kiran Kumar and Ram Gopal [10] reported exchangers are not available in the open literature. To fill in that
one-dimensional steady-state analysis of a rectangular NCL with void, this study presents CFD analysis of a 3-D CO2 based NCL with
end heat exchangers for low temperature applications. Recently end heat exchangers. Results are presented on the steady-state
behaviour of the loop at various operating pressures and temper-
atures. Operating parameter range is chosen such that the loop
* Corresponding author. Tel.: þ91 3222 282986. fluid (CO2) exists either as a subcritical single-phase fluid or as
E-mail address: ramg@[Link] (M. Ram Gopal). a supercritical single-phase fluid.
1359-4311/$ e see front matter Ó 2011 Elsevier Ltd. All rights reserved.
doi:10.1016/[Link].2011.10.031
A.K. Yadav et al. / Applied Thermal Engineering 36 (2012) 288e295 289
2. Physical model and mathematical formulations The following geometric and material specifications are
considered for the model:
2.1. Physical model Internal diameter of NCL (internal pipe), d ¼ 4 cm
Internal diameter of CHX and HHX (external pipe), D ¼ 6 cm
Fig. 1 shows the schematic of a rectangular NCL which consists Length of CHX and HHX, L ¼ 120 cm
of a cold heat exchanger (CHX), a hot heat exchanger (HHX), a riser Total width and height of NCL (L0 H0) ¼ 154 cm 124.5 cm
and a downcomer. The loop fluid is heated sensibly by extracting Total length of the loop (Lt) ¼ 545 cm
heat from the external fluid in HHX and is cooled sensibly by Insulated pipe length in horizontal pipe (L1) ¼ 17 cm
rejecting heat to the external fluid in the CHX. Circulation of the Tube wall thickness ¼ 3 mm; material: copper.
loop fluid is maintained due to the buoyancy effect caused by
heating at the bottom and cooling at the top.
2.2. Mathematical formulation and solution
The following assumptions are made in the analysis:
ZA
cp T rVdA
0
T ¼ (2)
ZA
cp rVdA
0
4m
Re ¼ (3)
pdm
g bd3 r2 QH0
Grm ¼ (4)
Am3 cp
where, Q ¼ mw cp;w DTw
All properties for Re and Grm are calculated at the average
temperature (Tavg) of the loop, which is expressed as,
TCHX þ THHX
Tavg ¼ (5)
2
where, TCHX and THHX are the water inlet temperatures at CHX and
HHX, respectively.
Fig. 2. Meshing of a cross section.
Modified Grashof number expressed in Eq. (4) is somewhat
different from classical Grashof number. Bau and Torrance [19]
prefer to call it a non-dimensional heating rate. However, the
meshing is done for axial direction (5 mm grid size in CHX and term QH/(Amcp) has the same dimensions of temperature difference
HHX, 20 mm for riser and downcomer). Mesh generation, imple- and if we consider it as reference temperature difference, then it is
mented in the GAMBIT platform, yielded a total of 131,904 nodes. appropriate to refer to it as a modified Grashof number [18].
Grid independence test was carried out to ensure optimal choice of Recently most of the authors [11,20,21] are using same definition of
fineness. For computational purposes, the following terms are modified Grashof number in the study of natural circulation loop.
defined.
Mass flow rate at any cross section is defined as,
2.3. Calculation of thermo-physical properties of CO2
ZA
rVdA Since the state of CO2 inside the loop varies from subcritical to
m ¼ (1)
supercritical and the variation in thermo-physical properties near
0
the critical point is extremely large, it is essential to calculate the
Mass weighted average (bulk mean) temperature of the fluid at properties by taking into account the temperature variation prop-
any cross section is defined as, erly. However, as shown in the literature, due to very small variation
in operating pressure throughout the NCL the effect of variation of
pressure on the properties of single-phase carbon dioxide is not
expected to be significant [10,11]. For example, results from the
14
present study show that the maximum variation of CO2 pressure is
90bar
12 35
Specific heat, c p (kJ/kgK)
25 70 bar
8 80 bar
90 bar
20 100 bar
6
15
4 10
5
2
0
304 312 320 328 336 344 352 250 275 300 325 350 375 400
Temperature (K) Temperature (K)
Fig. 3. Curve fit data for specific heat of supercritical CO2. Fig. 4. Variation of specific heat of CO2 with temperature at various pressures.
A.K. Yadav et al. / Applied Thermal Engineering 36 (2012) 288e295 291
10.22 kPa at an operating pressure of 90 bar (0.11% of operating with specific heat reaching the maximum at a given pressure. Fig. 4
pressure). Hence, for a given operating pressure, the properties of exhibits the effect of operating pressure on pseudo-critical point
CO2 at any point in the loop are calculated at the fixed operating with bulk mean temperature of fluid. As pressure increases,
pressure and local temperature. The required properties of CO2 pseudo-critical point for specific heat shifts towards higher
including density, specific heat, thermal conductivity and viscosity temperature.
are obtained from the NIST Standard Reference Database REFPROP
[22] and are considered to be temperature dependent in the calcu- 3. Results and discussions
lation. Properties of CO2 for the operating temperature range at
a temperature difference of 1 K are added to the fluid properties list In this study, water is employed as the external fluid in both CHX
in the Fluent, and a piecewise-linear interpolation approach is used and HHX. Inlet temperature of water in CHX is kept constant at
to calculate the properties within 1 K temperature difference. Fig. 3
shows the comparison of specific heat data used in Fluent for this
study with REFPROP data. Maximum variation with temperature is a 324
0.7
observed in case of specific heat (cp), while for the remaining
thermo-physical properties (density, thermal conductivity and 322
0.6
viscosity) the regression correlation coefficient is superior.
320 0.5
Temperature (K)
Velocity (m/s)
2.4. Pseudo-critical region
318 0.4
0.5
Temperature (K)
Velocity (m/s)
315 T, sec. 12 V, sec. 12
0.4
T, sec. 13 V, sec. 13
322
0.3
310
320 0.2
0 1 2 3 4 5 0.1
Length (m) 318
0.0
b 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0
CHX RIGHT LEG HHX LEFT LEG
2 Diameter (cm)
T o tal P ressu re d ifferen ce (kP a)
c 0.75
0
320.8
0.60
-2
320.4
Temperature (K)
Velocity (m/s)
0.45
-4
313 K
323 K 320.0 T, sec. 1 0.30
-6 V, sec. 1
333 K T, sec. 2 V, sec. 2
343 K T, sec. 3 V, sec. 3
T, sec. 4 V, sec. 4 0.15
-8 353 K 319.6
-10 0.00
319.2
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0
0 1 2 3 4 5
Diameter (cm)
Length (m)
Fig. 6. (a) Temperature and velocity profile at different cross sections in CHX at 333 K.
Fig. 5. (a) Variation of bulk mean temperature throughout the loop length. (b) Vari- (b) Temperature and velocity profile at different cross sections in HHX at 333 K.(c)
ation of total pressure difference throughout the loop length. Temperature and velocity profile at different cross sections in riser at 333 K.
292 A.K. Yadav et al. / Applied Thermal Engineering 36 (2012) 288e295
Fig. 7. Temperature contour plot for HHX water inlet temperature of 333 K at (a) Left leg (section 3), (b) CHX (section 6), (c) Right leg (section 9) and (d) HHX (section 12).
305 K and that in HHX is varied from 313 K to 353 K in steps of 10 K. region where density of the fluid is maximum leading to higher
Results are obtained for five operating pressures of CO2, i.e., 60, 70, pressure drop.
80, 90 and 100 bar. Operating pressure of the system is defined at
the centre of HHX. Mass flow rate of water in CHX as well as in HHX 3.2. Temperature and velocity profile at different cross sections
is assumed to remain constant at a value of 0.3 kg/s which ensures
turbulent flow on water side. Fig. 6 (a), (b) and (c) show the local temperature and local axial
velocity profiles at different cross sections in the CHX, HHX, and left
leg (riser) at a hot external fluid inlet temperature of 333 K and
3.1. Variation of temperature and pressure throughout the loop at a CO2 pressure of 90 bar. Variation of temperature and velocity
90 bar shown in the figures are drawn across the diameter at different
cross sections of the loop as defined in Fig. 1. Due to large variation
Fig. 5(a) and (b) show the variation of bulk mean temperature in density with temperature at this pressure strong buoyancy is
and total pressure difference of CO2 through the loop for varying produced. Unlike vertical sections, the combined effect of gravity
water inlet temperatures of HHX at an operating pressure of 90 bar. and local buoyancy in horizontal sections (CHX and HHX) leads to
Flow reversal is observed at a hot fluid inlet temperature of 343 K asymmetric variation of velocity and temperature. Thus, tempera-
and thus the functions of riser and downcomer are reversed. Hence, ture of fluid in the horizontal segments (CHX and HHX) increases
the CHX and HHX become parallel flow heat exchangers, since the toward the top at all the segments except at the exit of bends (in the
flow direction of external fluid is kept the same for all conditions. diagram, 0 is the bottom and 4 cm is the top). In the riser, at
One of the possible reasons for flow reversal is that the loop is a section far away from the bend (section 4), there is negligible
thermally and geometrically symmetrical. In this study it is temperature variation across the diameter of pipe. Velocity profiles
observed that external fluid temperature difference in CHX or HHX are also influenced by the centrifugal action caused by bends. Inside
is less than 1 K which shows that the loop is thermally almost the close loop, fluid at the outer part has higher velocity than at the
symmetrical. Chen et al. [12] also observed a similar flow reversal inner part, as is exhibited by all the plots.
phenomenon. Due to the assumption of adiabatic condition in the
riser and downcomer, the variation in temperature is almost 3.3. Temperature and velocity contour plots
negligible in these parts, whereas variations can be seen in CHX and
HHX due to heat transfer with the external fluid. Variation of total Figs. 7 and 8 show the velocity (m/s) and temperature (K)
pressure can be seen in riser and downcomer due to height of the contour plot for HHX water inlet temperature of 333 K at the centre
loop. Maximum variation of pressure in a loop is 10.22 kPa (0.11%) of left leg (section 3), CHX (section 6), right leg (section 9) and HHX
at an operating pressure of 90 bar. As temperature increases, (section 12). The isotherms and velocity vectors clearly show the
pressure drop for the loop decreases which is due to the decrease in non-uniform temperature and velocity variation inside the tube at
density at higher temperature. At a pressure of 90 bar and HHX a given cross section. As mentioned before, temperature at upper
water inlet temperature of 313 K, loop fluid is in the pseudo-critical part of CHX and HHX is higher than that at the lower part due to
Fig. 8. Velocity contour plot for HHX water inlet temperature of 333 K at (a) Left leg (section 3), (b) CHX (section 6), (c) Right leg (section 9) and (d) HHX (section 12).
A.K. Yadav et al. / Applied Thermal Engineering 36 (2012) 288e295 293
local buoyancy effect. In the riser (Fig. 7(a)) and downcomer comparison to mass flow rate starts at a lower pressure with HHX
(Fig. 7(c)), temperature is almost uniform over the cross section as water inlet temperature remaining the same. To know the pseudo-
there is no heat transfer from the wall except axial conduction. critical point, bulk mean temperature is needed which is taken as
Velocity contour also shows the same trend as explained in Fig. 6. an approximate average temperature of CHX and HHX water inlet
Since the temperature variation has a bearing on the stability of the temperatures.
loop, it is essential to capture it in order to understand the loop Fig. 9(b) also shows that as water inlet temperature of HHX
behaviour. This evidently justifies the use of a 3-dimensional increases, the heat transfer rate increases due to increase in
model. buoyancy effect. Even though there is decrease in mass flow rate at
higher temperature at a given pressure due to lower density, heat
3.4. Variation of loop fluid mass flow rate and loop heat transfer transfer rate does not decrease. This may be attributed to the fact
rate that at constant pressure, with increase in temperature, density of
the fluid decreases and near the critical point the viscosity and
Fig. 9(a) and (b) show the variation of CO2 mass flow rate and coefficient of thermal expansion decrease with temperature.
loop heat transfer rate with operating pressure at various HHX Decrease in viscosity with increase in temperature enhances the
water inlet temperatures. Results show that as operating temper- Reynolds number that contributes in enhancing heat transfer rate.
ature of loop fluid increases, mass flow rate as well as heat transfer
rate increase up to the pseudo-critical point and starts decreasing 3.5. Variation of heat transfer coefficient
beyond that. Mass flow rate and heat transfer rate are influenced
mainly by density and specific heat, respectively. Pseudo-critical Fig. 10 shows the variation of CO2 heat transfer coefficient with
point (temperature) for density at any pressure is lower than that operating pressure at different HHX water inlet temperatures for
of specific heat. In other words for a constant temperature situa- cooling. Heat transfer coefficient based on wall function is pre-
tion, pseudo-critical pressure for density is higher than that of sented here for cooling (CHX). Results show that at higher pressure
specific heat. Therefore, decrease in heat transfer rate in (90 and 100 bar), as operating temperature of loop fluid increases
heat transfer coefficient also increases initially and reaches
a maximum and then starts decreasing at higher temperature.
a 0.35
Results also show that as operating pressure increases peak of the
graph shifts towards the higher temperature due to shifting of the
313 K
0.30 pseudo-critical point. Heat transfer coefficient for heating is also
323 K
333 K calculated for all the cases and a similar trend is observed.
Mass flow rate (kg/s)
343 K
0.25 353 K 3.6. Comparison of heat transfer coefficients
2000 323 K
333 K 90 bar
100 bar
Heat transfer rate (W)
343 K 2000
1600 353 K
1600
1200
1200
800
800
400
400
0
60 70 80 90 100 310 320 330 340 350
Pressure (bar) Temperature (K)
Fig. 9. (a) Variation of mass flow rate of CO2 with HHX inlet temperature. (b) Variation Fig. 10. Variation of heat transfer coefficient for different operating pressure for
of heat transfer rate of CO2 with HHX inlet temperature. cooling (CHX).
294 A.K. Yadav et al. / Applied Thermal Engineering 36 (2012) 288e295
2400 Fluent (Heating) the above mentioned range of Reynolds number. Correlation has
2
Dittus-Boelter (Cooling)
been developed for a steady, single-phase natural circulation loop.
Dittus-Boelter (Heating)
2100 Gnielinsky
All Properties used in the correlation are taken at average
temperature of the loop.
1800
4. Conclusions
1500
In the present study, results obtained from CFD analysis of
a carbon dioxide based, single-phase (subcritical and supercritical)
1200 NCL with end heat exchangers have been presented. Steady flow
simulation of the 3-dimensional model of a rectangular NCL has
900 been implemented. The following conclusions are made after the
discussion of the different cases:
600
310 320 330 340 350 (i) Results show that due to the presence of bends and strong
Temperature (K) buoyancy effects near pseudo-critical zone, fluid parameters
such as local velocity and temperature vary in all three
Fig. 11. Comparison of heat transfer coefficient with different correlations at 90 bar. dimensions.
A.K. Yadav et al. / Applied Thermal Engineering 36 (2012) 288e295 295
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