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Description
The current research is based on the principles of three-dimensional discrete element method (3D – DEM) through simulations, by using heat transfer models in EDEM, to investigate the effects of fill level, rotation rate and particle size on the steady-state conduction heat transfer in rotary drums. The high heat and mass transfer rates obtained through rotary drums make them very useful for powder mixing and heating processes in metallurgical, cement, mining, pharmaceutical, detergent and other particulate processing applications. However, these complex processes are difficult to model and operate since the particles can have a wide range of properties, and there is currently no way to predict the optimal operating conditions for a given material.
Steady-state heat transfer by conduction forms the basis for understanding other steady-state and unsteady-state heat transfer in a rotary drum – conduction, convection and radiation. Statistical analysis is carried out to determine the effects of these process parameters and find optimal operating conditions, which will thereby improve the heat transfer efficiency in rotary drums. A stainless-steel drum with a diameter of 6 inches and a length of 3 inches was modeled in EDEM with silica beads of sizes 2 mm, 3 mm and 4 mm at fill levels of 10%, 17.5% and 25%, and at rotation rates of 2 rpm, 5 rpm and 10 rpm. It was found that the heating uniformity increased with decreasing particle size, decreasing fill level and increasing rotation rate. This research is the first step towards studying the other heat transfer modes and various other process parameters. Better understanding of the various heat transfer modes, when used in combination for heating the particles, will be beneficial in improving the operating efficiency, reducing material costs and leading to significant energy conservation on a global scale.
Steady-state heat transfer by conduction forms the basis for understanding other steady-state and unsteady-state heat transfer in a rotary drum – conduction, convection and radiation. Statistical analysis is carried out to determine the effects of these process parameters and find optimal operating conditions, which will thereby improve the heat transfer efficiency in rotary drums. A stainless-steel drum with a diameter of 6 inches and a length of 3 inches was modeled in EDEM with silica beads of sizes 2 mm, 3 mm and 4 mm at fill levels of 10%, 17.5% and 25%, and at rotation rates of 2 rpm, 5 rpm and 10 rpm. It was found that the heating uniformity increased with decreasing particle size, decreasing fill level and increasing rotation rate. This research is the first step towards studying the other heat transfer modes and various other process parameters. Better understanding of the various heat transfer modes, when used in combination for heating the particles, will be beneficial in improving the operating efficiency, reducing material costs and leading to significant energy conservation on a global scale.
ContributorsBheda, Bhaumik (Author) / Emady, Heather (Thesis advisor) / Muhich, Christopher (Committee member) / Nielsen, David (Committee member) / Arizona State University (Publisher)
Created2020
Description
Thermophotovoltaic energy conversion is seen as a viable option for efficiently converting heat to electricity. There are three key components to a thermophotovoltaic (TPV) system: a heat source, a heat emitter and a photovoltaic (PV) cell. A heat source heats up the emitter which causes the emitter to release thermal radiation. The photons are absorbed by a PV cell when they are acting above the bandgap energy. The PV cell then generates electricity from this thermal radiation. In theory, efficiency of a TPV system can be well above 50%. In order for TPV to reach large-scale adaptation, an efficiency at or above 20% is needed. In this project, a high-temperature heater capable of reaching 1000K was developed. The heater involved a copper block machined to hold two cartridge heaters, as well as two thermocouples. It has an accompanying copper lid that can be screwed tight to the main block, with an emitter in between. There is an aperture to allow radiation through the casing towards the PV cell. Preliminary thermal analysis showed that the heater provides uniform temperature distribution across the emitter, which is necessary for proper radiation. A mounting system was also designed to implement the heater into the overall TPV system. Current work is being done to lower the radiation loss from the heater and mounting system, as well as implementation of all auxiliary components to begin testing. The maximum temperature of the heater, radiation heat flux received by the cell, and overall power output and efficiency of the system will be tested.
ContributorsDeffigos, Nikolas (Author) / Wang, Liping (Thesis director) / Milcarek, Ryan (Committee member) / Ni, Qing (Committee member) / Barrett, The Honors College (Contributor) / Mechanical and Aerospace Engineering Program (Contributor)
Created2021-12
Description
This thesis project explains what thermal interface materials (TIMs) are, what they are used for, and how to measure their properties. Thermal interface materials are typically either a grease like paste or a soft polymer pad that is placed between two solids to increase the heat transfer rate. Solids in contact with each other experience a very large thermal contact resistance, this creates a thermal bottleneck which severely decreases the heat transfer from one solid to another. To solve this, particles with a high thermal conductivity are used as filler material in either a grease or polymer. A common application for TIMs is in computer components, where a TIM is used to remove the heat generated from computer chips. These materials allow for computer chips to run faster without overheating or throttling performance. However, further improvements to TIMs are still desired, which are needed for more powerful computer chips. In this work, a Stepped Bar Apparatus (SBA) is used to evaluate the thermal properties of TIMs. The SBA is based on Fourier’s Law of one-dimensional heat transfer. This work explains the fundamentals of the SBA measurement, and develops a reliable way to confirm the SBA’s measurement consistency through the use of reference samples. Furthermore, this work evaluates the effects of volume fraction and magnetic alignment on the performance of nickel flakes mixed into a polymer to create a soft TIM composite pad. Magnets are used to align the nickel flakes into a column like arrangement in the direction that heat will travel. Magnetic alignment increases the thermal conductivity of the composite pads, and has peak performance at low compression.
ContributorsHart, Matthew (Author) / Rykaczewski, Konrad (Thesis director) / Wang, Robert (Committee member) / Mechanical and Aerospace Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2019-12
Description
The ASU Compact X-ray Free Electron Laser (CXFEL) is a first of its kind instrument that will illuminate the processes of life and allow scientists to create more effective treatments for disease. The dimensions of the linear accelerator (LINAC) cavities must remain stable during operation, for a change in the geometry alters the standing wave microwave energy resonance within the cavities and leads to reflected rather than coupled and useful microwave energy to electric field coupling. This disturbs the electron bunch acceleration dynamics critical to the ultimate generation of x-ray pulses. Cooling water must be supplied to the electron generating RF-GUN, and linear accelerator (LINAC) structures at unique flowrate and temperature setpoints that are specific to the operating mode of the CXFEL. Design specifications for the water supply to the RF-GUN and three LINACs and were made for the nominal operating mode, which adds a 3 kW heat load to the water. To maintain steady cavity dimensions, water must be supplied to each device under test at 30.0 ºC ± 0.06 ºC. The flowrate of water must be 3.5 GPM to the RF-GUN and 2.5 GPM to each of the three LINACs with ± 0.01 GPM flowrate resolution. The primary function of the Dedicated-Precision Thermal Trim Unit (D-PTTU) is to control the flowrate and temperature of water supply to each device under test. A simplified model of the system was developed to select valves that would meet our design specifications for flowrate and temperature control. After using this model for valve selection, a detailed system model was created to simulate relevant coupled-domain physics of the integrated system. The detailed system model was used to determine the critical sensitivities of the system and will be used to optimize the performance of the system in the future. Before the detailed system model can be verified and tuned with experiments, the sensors were calibrated in an ice-bath to ensure the sensors measure accurate and precise values. During initial testing, the D-PTTU was able to achieve ± 0.02 ºC temperature resolution, which exceeds the design specification by a factor of three.
ContributorsGardeck, Alex John (Author) / Holl, Mark (Thesis director) / Smith, Dean (Committee member) / Department of Physics (Contributor) / Mechanical and Aerospace Engineering Program (Contributor, Contributor) / Barrett, The Honors College (Contributor)
Created2020-05
Description
The temperature of exhaust pipes can be dangerous in dry areas where there is a lot of brush. The temperatures of exhaust pipes can reach a high enough temperature to start a fire if touching the dry brush, which ignites around 300°C. The goal of this project was to explore different techniques to limit the possibility of these brush fires. Specifically, different methods were explored to reduce the temperature of the pipe that would be contacting the brush. Fires can begin within seconds of contacting the hot exhaust pipes [10]. This experiment found that of the three options tested: exhaust wrap, heat sink with thermoelectric devices, and high temperature paint, adding a heat shield/sink is the best way to limit the high temperatures from igniting the brush. There was a cooling difference of nearly 100°C when a heat shield/sink was added to the bare pipe. The additional thermal mass as well as the finned heat sinks attached to the heat sink helped dissipate the heat from the pipe and release the waste heat into the surroundings. The increase in surface area in correspondence with forced convection from the surrounding air lowered the temperature of the metal in contact with the dry brush.
ContributorsHodges, Andrew (Author) / Benson, David (Thesis director) / Bocanegra, Luis (Committee member) / Mechanical and Aerospace Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2020-05
Description
Nuclear power has recently experienced a resurgence in interest due to its ability to generate significant amounts of relatively clean energy. However, the overall size of nuclear power plants still poses a problem to future advancements. The bulkiness of components in the plant contribute to longer construction times, higher building and maintenance costs, and the isolation of nuclear plants from populated areas. The goal of this project was to analyze the thermal performance of nanocrystalline copper tantalum (NC Cu-Ta) inside the steam generator of a pressurized water reactor to see how much the size of these units could be reduced without affecting the amount of heat transferred through it. The analysis revealed that using this material, with its higher thermal conductivity than the traditional Inconel Alloy 600 that is typically used in steam generators, it is possible to reduce the height of a steam generator from 21 meters to about 18.6 meters, signifying a 11.6% reduction in height. This analysis also revealed a diminishing return that occurs with increasing the thermal conductivity on both reducing the required heat transfer area and increasing the overall heat transfer coefficient.
ContributorsRiese, Alexander (Author) / Phelan, Patrick (Thesis director) / Bocanegra, Luis (Committee member) / Mechanical and Aerospace Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2019-05