Experimental and Numerical Study on the Fluid Dynamics and Exergetic Performance of the Heat Exchanger in an Industrial Corn Drying System

Abstract

The heat exchanger is the key component of an industrial drying system. The present work introduced a novel tube heat exchanger into a corn drying system. To fully understand the heat exchange process and optimize the heat exchange performance of the heat exchanger, numerical simulation, exergy analysis and economic analysis methodologies were adopted to analyze the comprehensive performance of the heat exchanger. The fluid dynamics as well as the exergy performance of the heat exchanger under different flue gas velocities (3, 5 and 7m/s) and different ambient air relative humidities (80%, 85% and 90%) were investigated. The results showed that there are two strong turbulences causing the huge pressure drop at the last two stages of the flue gas duct, while there are two insufficient heat exchange areas on both sides of the heat exchanger; thus, the corresponding improvement recommendations were proposed in the present work. The values of the Re and Nu were found to vary in the range of 1256.275–2210.554 and 21.337–32.415, respectively. The average heat transfer coefficients were ascertained to be above 8.274 kW·m−2·K−1, while the pressure drop of the ambient air was ascertained to be under 16.138 Pa. Moreover, the exergy analysis revealed that the heat exchanger experiences sustainable development (SI < 2), and the exergy efficiency is above 11.461%. The main results may provide some references for further optimizing the heat transfer performance of the heat exchanger.