A Diddertatiop Presentation

A Dissertation Presentation
on
Thermo-Hydraulic
Performance of Square
Perforated Solar Air Heater
Guided By:
Submitted By:
Dr. B. K. Maheshwari
Assistant professor
Rahul Tripathi
M.E. (Thermal Engg.)
DEPARTMENT OF MECHANICAL ENGINEERING

M. B. M. ENGINEERING COLLEGE
FACULTY OF ENGINEERING AND ARCHITECTURE
J. N. V. UNIVERSITY, JODHPUR
June, 2014
Contents Of Dissertation
Performance Enhancement Of Solar Air Heater Using
Baffles
Experimental Setup And Programme
Result And Graphs
Conclusions
References
4/26/15
M.E. Dissertation by Rahul Tripathi
PERFORMANCE ENHANCEMENT OF SOLAR

AIR HEATER USING BAFFLES
Perforated Rectangular Blocks

Asymmetrically Heated Rectangular Duct with
Perforated Baffles
Use of Porous Baffles to Enhance Heat Transfer
Fully perforated ribs
Half perforated turbulence promoters
Fins provided with baffles
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Perforated Rectangular Blocks

Sara et al. (2001) had investigated
perforated rectangular crosssectional.
Results from the perforated blocks
concluded that as the degree of the
perforation increased the heattransfer enhancement capability of
the blocks also increased.
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A typical variation in
the heat transfer with Re
for varying degree of the
perforated
open-area
ratio (=0.05, 0.10 and
0.15) is shown in Figure.
With
their
experimental
studies
they have concluded that
perforations
in
the
blocks enhance the heat
transfer
and
the
enhancement increases
with
increasing
the
degree of perforations.
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Fig. Variation of with Re (Sara et al,

2001)
Asymmetrically Heated Rectangular

Duct with Perforated Baffles
Maheshwari
et
al.
(2005)
has
experimentally studied the heat transfer
and friction factor of rectangular ducts
with baffles ( = 18.4%, 28.4%, 41.7% &
46.8%)
They have concluded that the baffles with
the highest open area ratio (46.8%) give
the best performance compared with the
smooth duct at equal pumping power.
4/26/15
The longitudinal section of the duct is shown in Fig.(a)

and (b) shows two views of a perforated baffle.
Fig. (a) Schematic of the baffled duct, (b) sketch of a

baffle with perforations. (Karwa et al 2005).
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Fig. Thermal performance at equal pumping power.

(Karwa et al. 2005)
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Use of Porous Baffles to Enhance Heat

Transfer
Anand and Ko (2003) have experimentally studied heat transfer enhancement
in a rectangular channel by using a porous baffle made up of aluminum foam.
Baffles were mounted on bottom and top walls in a staggered fashion. Porous
baffles as shown in Fig.
Fig. Aluminium foam structure (Anand and Ko 2003)

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The heat transfer enhancement ratio (Nu+) decreases with

increase in Reynolds number and increases with increase in pore
density.
Fig. Heat transfer enhancement ratio of different pore density.

( Anand and Ko,2003 ).
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Fully Perforated Ribs

Hwang and Liou (1995) investigated heat transfer and friction in a rectangular
channel (W/H=4) with symmetrically mounted solid and fully perforated ribs on
parallel broad walls (=50%, e/H=0.13 and 0.26, /e=0.38 and 0.76, Re=10,000
50,000, p/e=520).
Their studies had also concluded that the perforated ribs are thermohydrolically
better than the solid ribs.
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11
Half Perforated Turbulence Promoters

Tanasawa et al. investigated the effect of the half perforated turbulence promoters
symmetrically mounted on two opposite walls on the heat transfer and friction in a
rectangular channel.
They found that surfaces with the half perforated turbulence promoters with
perforations on the lower half of the ribs performed better than those with the solid
type promoters.
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12
Fins Provided with Baffles

Yeh and Chou (1991) experimentally investigate the efficiency of solar air heaters
with baffles as shown in Fig. and found considerable improvement in the collector
efficiency of solar air heaters with fins in the collector are provided with attached
baffles to create air turbulence and an extended heat transfer area and on increasing
the density of baffles.
Fig. Baffle attached to absorber plate. (Yeh and Chou, 1991)
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13
Roughness elements of larger height give a high increase in the heat transfer
but increase in pressure drop is a serious concern. Hot zones develop in the
wake of these elements because of re-circulating flow. This leads to lower heat
transfer from these zones; thus an attempt has been made by the designers to
overcome this effect by putting perforation in the baffles which increase the
heat transfer from these zones and help in reducing the pressure drop across the
channel. The perforated elements allow a part of the flow to pass through these
perforations and thus the hot zones and form drag are reduced.
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14
Experimental Setup And Programme

Experimental investigation of heat transfer and friction characteristics of a
rectangular duct with square perforated baffles on one broad wall which is subjected
to solar radiation has been carried out using an outdoor test facility available in
department of mechanical engineering. The test facility has been designed
according to the guide line of ASHRAE standard 93-1986 for testing of solar
collector operating in an open-loop mode.
Instrumentation
Solar Radiation Measurement
A pyranometer (shown in figure ) was used to measure the total
short wave radiation from both sun and sky and a pyrheliometer
wad used to measure the direct normal insulation.
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15
Fig. Pyranometer Solar radiation measuring instrument

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16
Temperature Measurement
In present investigation a Butt-welded 1 mm dia Chromel Alumel bead (Ktype) thermocouples having temperature range 0o-1200oC , calibrated against
mercury thermometer of 0.1oC least count, was used for the temperature
measurement.
Fig. Thermocouple measurement circuit

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The thermocouples(3/24 inch diameter K type CR/AL (Compensating)PVC

THERMOCOUPLE Indian Standards IS 8784 STANDARD. confirmation ECO
SERIES) were provided along the axial center line of the absorber plate in small
holes on the span-wise variation of absorber plate temperature as shown in fig.
Nineteen (19) thermocouple arranged span-wise in the duct, as shown in the fig.
To measure the exit air temperature after the mixing section three thermocouples
were provided as shown in figure.
Inlet temperature of air to the duct was also measured using a thermocouple in
the same manner.
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18
Fig. (a) Thermocouple positions of baffled absorber plate.

(b) Thermocouple positions of smooth absorber plate.
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19
Fig. Thermocouple locations on Smooth and Baffled plates in Solar Air Heater.
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20
Air Flow Measurements

For flow measurement an orifice plate (as shown in fig.) and
inclined manometers with tilt of 5:1 had been used to achieve the
desired accuracy in present investigation.
Fig. Detailed view of orifice plate (Gharai et al,

2011)
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21
Pressure Drop across Collector

The static pressure drop across the solar collector was measured using a
differential pressure measuring device. Each side of the device was connected to
four externally main folded pressure taps as shown in Fig. The pressure taps
consist of 6.4 mm nipples soldered to the duct and centered overt mm diameter
holes. The edge of these holes on the inside surface of duct was made sure to be
free from burrs and other surface irregularities.
Fig. Schematic representation of the measurement of pressure drop across the solar
collector.(ASHRAE Codes ,93-1986)
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Wind Velocity
The wind velocity was measured with an instrument (shown in figure) and
associated readout device that can determine the integrated average wind velocity
for each test period accuracy of 0.8 m/s (1.8 mph)
Fig Wind velocity measurement

device
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23
Apparatus and Method of Testing

The experimental test facility, designed and fabricated as per ASHRAE
Standard for testing of solar collectors (ASHRAE Standards, 1986), consists of
300 mm wide parallel ducts with entrance, test, exit and mixing sections, a blower,
control valves, orifice plates and provision for temperature and pressure drop
measurements as shown in Fig. (a) and (b). It works in an open loop mode.
The ducts are made of good quality smooth faced plywood and wooden
boards. Each duct is 2880 mm long consisting of 1.64 m long test section, 550 mm
long insulated entry and exit sections are installed to reduce any upstream and
downstream effect due to entrance and exit section respectively on the test section.
For the turbulent flow regime, ASHRAE Standard recommends entry and
exit lengths of 5(WH) and 2.5(WH), respectively, i.e. 526 mm and 263 mm,
respectively for the duct cross-section employed in the present investigation.
The height of both the ducts has been kept fixed at 38.4 mm. The combined
width of ducts (with side walls) is 850 mm where ducts being 300mm wide as
shown in figure.
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24
Fig (a) and (b) Plan and Elevation of Solar Air Heater.
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25
The test section length is 1.64 m resulting in length to hydraulic diameter (D=38.4
mm) ratio of 24.3. Topside of the heated test section carries 12 pieces of 3.25 mm
thick aluminium plate with square perforated baffles on the lower side.
Fig. Sectional view of solar air heater
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26
The sun facing sides of both the absorber plates are smooth and blackened.
Glass plates of 5 mm thickness have been used as cover over the absorber plates at a
height of 60 mm. The top side of entry and exit lengths of each duct is covered with
the plywood.
A 100 mm long baffled mixing section is provided to get uniform temperature
of the exit air in the measuring section just after the mixing section. The exit end of
each duct is connected, through a rectangular to circular transition piece, to a 70 mm
ID G.I. pipe with orifice plate assembly.
The other end of the each pipe is connected through control valve to the
suction of a 10 HP blower using flexible pipe and a Y-section (not shown in the
figure).
50 mm thick thermocole insulation has been provided on the back of the
collector from test section inlet to outlet of twin duct while the transition pieces and
orifice plate assembly pipes (up to the orifice plates) are covered with foam blanket
insulation.
All joints are properly sealed with putty.
The set-up was installed horizontal (in north-south orientation) on the roof top
at a height of 750 mm on an iron stand.
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27
thermocouples have been fixed with M-seal in the sun facing side of
absorber plate in small diameter holes drilled about 2.5 mm deep at nineteen axial
and span wise locations on the smooth and baffled absorber plates, respectively.
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Assembly and Fabrication of the Experimental setup

Below are images for the sequence of assembly and fabrication of solar air heater
experimentation.
Fig Wooden Frame of the solar air heater

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Fig. Valves, Pipe fitings, and insulation used for solar air heater
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30
Fig. Rectangular (300x38.4 mm2) to circular transition piece(70 mm ID), G.I. pipe with
orifice plate assembly. The throat diameter of the orifice plate is 38 mm. The other end
of the each pipe is connected through control valve
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Fig Finished Solar Air Heater Wooden Frame and pipe fitting
4/26/15
32
Fig. .Final Assembly of transition piece and

control valves on solar air heater
4/26/15
Fig 3.25 mm thick Aluminium sheet

used for fabrication of smooth and
baffled absorber plates
33
Fig. Hand punching machine used for fabrication of baffles

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Fig Punching die of square shape.

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35
Fig Assembly of Smooth and Rough Plates on Twin Duct Solar Air Heater.
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Fig. Attachment of Thermocouples on absorber plates

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37
Fig Blackened Absorber plates for increased absorptivity

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38
Fig. Complete Fabrication of solar air Heater with Glass plate Covers
4/26/15
39
Experimental Conditions and Procedure

All components of the experimental set up and the instrument have been
checked for proper operation. The blower was then switched on and the joints of the
setup were properly sealed to prevent leakage.
Micro-manometer and inclined U-tube manometer were properly leveled.
Blower was switched on and the flow control valve was adjusted to give a
predetermined rate of air flow through the test section.
Before the covers were put off, it was ensured that all the thermocouples gave
the same output.
All reading was noted under steady state condition, which was assumed to
have been obtained when the plate and air outlet temperature did not deviate over a
10 minute period.
The steady state for each run was obtained in about 1 hour and two Reynolds
numbers was investigated throughout the day in the following manner.
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40
Table : Experimentation Plan
Day 1
Day 2
Day 3
Day 4
Day 5
Day 6
Nov.-13
Nov.-14
Nov.-15
Nov.-16
Nov.-17
Nov.-18
=42.70%
=42.70%
=51.98%
=51.98%
=60.69%
=60.69%
Re=3000
and
Re=6000
Re=9000
and
Re=12000
Re=3000
and
Re=6000
Re=9000
and
Re=12000
Re=3000
and
Re=6000
Re=9000
and
Re=12000
4/26/15
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Table : Experimental conditions and dimensions of baffle and duct

Reynolds number, Re
3034 12003
Duct depth, H
38.4 mm
Width of duct, W
300 mm
Hydraulic Diameter, D
68.16 mm
Duct aspect ratio, W/H
7.81
Test section length, L
1640 mm
Test section length to hydraulic diameter ratio, 24.06

L/D
Thickness of baffle,
0.643 mm
Baffle height, e
19 mm
Spacing between baffles (pitch), p
134.1 mm
Baffle height-to-duct height ratio, e/H
0.495
Baffle thickness-to-height ratio, /e
0.034
Baffle pitch-to-height ratio, p/e
7.06
Open area ratio of perforated baffle,
Type I
= 42.70%
Type II
= 51.98%
Type III
= 60.69%
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Fig. Details and dimensions of square perforated baffles of open area

ratio =60.69%.
4/26/15
43
Fig. Details and dimensions of square perforated baffles of open area ratio =51.98%.
4/26/15
44
Fig. Details and dimensions of square perforated baffles of open area ratio =42.70%.
4/26/15
45
Fig. Detailed nomenclature and various parameters of baffle
4/26/15
46
The studies (Han et al., 1978; Han and Park, 1988; Han et al., 1989) show that
the effect of the values of the friction factor and the heat transfer either vanishes or is
only marginal when the aspect ratio is greater than 8. It is to be noted that the solar air
heaters have generally high aspect ratio duct. Keeping the above information in the
mind, the value of the baffle height-to-duct height ratio, (e/H), baffle thickness-toheight ratio, (/e), baffle pitch-to-height ratio, (p/e), and the duct aspect ratio, (W/H)
have been fixed for the present study. Only Open area ratio of perforated baffle, (),
have been varied and three values were selected, (i.e. 60.69%, 51.98%, and 42.70%).
While the baffles height has been fixed at 19 mm. The airflow rate was varied to
give flow Reynolds number of about 3034 to 12003.
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Perforated Baffles
The details of baffles used in this study and other relevant system parameters
are given in previous Tables and figures. In the present study, the baffle height-to-duct
height ratio e/H has been fixed at 0.495, which reduces flow passage blockage effect
and simultaneously the baffles extend sufficiently deeper into the flow into the buffer
zone. The baffle pitch- to- height ratio p/e is 7.06 and the flow Reynolds number study
ranges from 3000-12000.
The ratio of the area of the perforations to the baffle frontal area is known as
open area ratio and is given by
= n a2 / (be)
where n is the number of the holes punched through the baffle and a is the side
of a square hole
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Data Reduction
Mass flow rate of air has been determined from pressure drop
measurement across the orifice plate using the following relationship:
The heat transfer coefficient for the heated test section was calculated from:
Where the heat transfer rate Qu, to the air is given by

The heat transfer coefficient has been used to determine the Nusselt number
using the equation
Where
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49
The Reynolds number was determined from the value of the mass flow rate,
m, using the equation:
Where
The friction factor was determined from the measured values of pressure drop,
The thermo physical properties of the air have been taken at the
corresponding mean temperature Tm = Tfm or Tmpg. The following relations of
thermo physical properties, obtained by correlating data from NBS (U.S.), have
been used:
4/26/15
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RESULT AND GRAPHS

Variation of Nusselt Number with Reynolds Number
The Comparative plot of Nusselt number v/s Reynolds number has been shown in
Fig. for smooth and baffled duct of different perforations (i.e., = 60.69%,
51.98%, and 43.70%).
120
Smooth Plate
=42.70% Perforated Baffles
100
N usselt N umber (N u)
80
60
40
20
0
2000
4000
6000
8000
10000
12000
14000
Reynolds Number (Re)
Fig Variation of Nusselt Number with Reynolds Number

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The enhancement in Nusselt number for baffled plate of open area ratio
=42.70% is found highest and is order of 1.36-2.09 times more than smooth
plate. It is to be noted that value of Nusselt number is directly related to
change in heat transfer coefficient. And eventually we get better heat transfer
coefficient for baffled plates as compared to the smooth plate.
Variation of Nusse lt Numbe r ratio (Nu/Nus ) with Re ynold Numbe r (Re )
3
2.5
Smooth Plate
Nusselt Number ratio (Nu/Nus )

1.5
1
0.5
0
2000
4000
6000
8000
10000
12000
14000

Fig. Plot of Nusselt
number ratio versus the Reynolds number
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Variation of Friction Factor with Reynolds Number

As shown in Fig variation of friction factor has been found in good
agreement with theoretical value given by Moodys Chart
Smooth
0.1
0.09
0.08
Friction Factor (f)
0.07
0.06
0.05
0.04
0.03
0.02
0.01
0
2000
4000
6000
8000
10000
12000
14000
Fig Variation of Friction factor with Reynolds Number

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53
In the present experimentation study there was an enhancement of 1.362.09 times in Nusselt number while friction factor increased 1.91-2.19 times for
the baffle of open area ratio =42.70%.
It is found in the study that friction factor increment for other two baffles
of open area ratio =51.98% and 60.69% are 1.77-2.10 and 1.49-1.7
respectively.
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Variation of Temperature Rise with Mass Flow Rate

From the figure 4.4 if is cleat that Temperature Rise for baffled plates are higher
than smooth plates with same value of mass flow rates and solar insolation
Smooth
18
16
14
(To -Ti ) Temperature Rise (o C)
12
10
8
6
4
2
0
0.01
0.01
0.02
0.02
0.03
0.03
0.04
0.04
Mass Flow Rate (m/s)
Fig Variation of Temperature Rise with Mass Flow Rate

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Thermo-Hydraulic Performance Parameter

Lewis [1975] proposed a thermo-hydraulic performance parameter known as
efficiency parameter h, which evaluates the enhancement of heat transfer for same
pumping power requirement and is defined as,
Smooth Plate
1 /3
(S t/S ts)/(f/fs)
1.8
1.6
1.4
1.2
1
0.8
0.6
0.4
0.2
0
2000
4000
6000
8000
10000
12000
14000
Fig Thermo-hydraulic Performance Parameter

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56
Thermo-hydraulic Performance Parameter for square perforated baffle

are found greater than unity it is found 1.49, 1.75, 1,86 and 1.87 for baffle of
open area ratio =60.70% for different Reynolds number range investigated in
the study between 3034 to 12003.
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Comparison of Square and Circular Perforated Baffles

Maheshwari et. al, 2005, experimentally investigates the circular perforated baffles
of four different open area ratios 18.4%, 28.4%, 41.7% and 46.8%. He found that the
baffle of open area ratio of 46.8% give the greatest performance advantage.
=60.69% square perforated baffles
=46.8% circular perforated baffles
2
1.8
1.6
1.4
1.2
Ratio of Nusselt Number (Nu/Nus)
1
0.8
0.6
0.4
0.2
0
2000
4000
6000
8000
10000
12000
14000
Fig. Plot of Nusselt number ratio versus the Reynolds number for circular and
square perforated baffles.
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They concluded that increasing the open area ratio increase the performance
of the heater but in case of circular perforation it is not possible to increase the open
area ratio more than 46.8%. I opted square perforation and in it, it is possible to
increase the perforation to a limit of 60.69%.
In this experimental study it is found that for the square perforated baffle of
open area ratio of 60.69% is the best one. By comparing it with circular perforated
baffle of 46.8% perforation, increment in Nusselt number is more by 21%.
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By the comparing of thermo hydraulic performance of 60.69% square

perforated baffles and 46.8% circular perforated baffles it is found that 60.69%
square perforated baffles are thermo hydraulically better than 46.8% circular
perforated baffles by 18%
=46.8% circular perforated baffles
2
1.8
(St/Sts)/(f/fs)1/3
1.6
1.4
1.2
1
0.8
0.6
0.4
0.2
0
2000
4000
6000
8000
10000
Reynolds Number
12000
14000
Fig Comparison of thermo hydraulic performance of 60.69% square perforated

baffles and 46.8% circular perforated baffles
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60
CONCLUSIONS
Nusselt number enhancement by use of square perforated baffles of different
open area ratios was found to be in the range of 1.36 to 2.09 times to the
corresponding values of smooth plate for the Reynolds Number 3034 to 12003.
Increment in Friction factor (power penalty) was found 1.91-2.19, 1.77-2.10 1.49-1.7
for the baffle of open area ratio =42.70%, =51.98% and 60.69% respectively to the
corresponding values of smooth plate for the Reynolds Number 3034 to 12003.
Nusselt number increases whereas friction factor decreases with increase of
Reynolds number. Values of friction factor and Nusselt number were highest for
perforated baffle of open area ratio =42.70% and was lowest for perforated baffle of
open area ratio =60.69% but . This is due to change in flow characteristics because of
baffles that cause flow separation, reattachments and generation of secondary flow.
Thermo-hydraulic Performance Parameter for square perforated baffle are
found greater than unity it is found 1.87, 1.70, and 1.55 for baffle of open area ratio
=60.69%, 51.98% and 42.70% respectively for different Reynolds number range
investigated in the study between 3034 to 12003.
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The ratio of Nusselt number of baffled duct to smooth duct was found in the
range of 1.59 to 1.88 for the Reynolds no. of 3034 to 12003 for square perforated
baffles of open area ratio of 60.69% but for circular perforated baffles of open area
ratio of 46.8% it was reported in the range of 1.45 to 1.55 by Maheshwari et. al,
2005. So it is concluded that square perforated baffles of 60.69% perforation are
better than circular perforated baffles of 46.8% perforation.
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62
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Thank You
Any Queries
4/26/15
68

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A Dissertation Presentation

DEPARTMENT OF MECHANICAL ENGINEERING

M.E. Dissertation by Rahul Tripathi

PERFORMANCE ENHANCEMENT OF SOLAR

Perforated Rectangular Blocks

M.E. Dissertation by Rahul Tripathi

Perforated Rectangular Blocks

M.E. Dissertation by Rahul Tripathi

Fig. Variation of with Re (Sara et al,

M.E. Dissertation by Rahul Tripathi

Asymmetrically Heated Rectangular

M.E. Dissertation by Rahul Tripathi

The longitudinal section of the duct is shown in Fig.(a)

Fig. (a) Schematic of the baffled duct, (b) sketch of a

M.E. Dissertation by Rahul Tripathi

Fig. Thermal performance at equal pumping power.

M.E. Dissertation by Rahul Tripathi

Use of Porous Baffles to Enhance Heat

Fig. Aluminium foam structure (Anand and Ko 2003)

M.E. Dissertation by Rahul Tripathi

The heat transfer enhancement ratio (Nu+) decreases with

Fig. Heat transfer enhancement ratio of different pore density.

M.E. Dissertation by Rahul Tripathi

Fully Perforated Ribs

M.E. Dissertation by Rahul Tripathi

Half Perforated Turbulence Promoters

M.E. Dissertation by Rahul Tripathi

Fins Provided with Baffles

Fig. Baffle attached to absorber plate. (Yeh and Chou, 1991)

M.E. Dissertation by Rahul Tripathi

M.E. Dissertation by Rahul Tripathi

Experimental Setup And Programme

M.E. Dissertation by Rahul Tripathi

Fig. Pyranometer Solar radiation measuring instrument

M.E. Dissertation by Rahul Tripathi

Fig. Thermocouple measurement circuit

M.E. Dissertation by Rahul Tripathi

The thermocouples(3/24 inch diameter K type CR/AL (Compensating)PVC

M.E. Dissertation by Rahul Tripathi

Fig. (a) Thermocouple positions of baffled absorber plate.

M.E. Dissertation by Rahul Tripathi

M.E. Dissertation by Rahul Tripathi

Air Flow Measurements

Fig. Detailed view of orifice plate (Gharai et al,

M.E. Dissertation by Rahul Tripathi

Pressure Drop across Collector

M.E. Dissertation by Rahul Tripathi

Fig Wind velocity measurement

M.E. Dissertation by Rahul Tripathi

Apparatus and Method of Testing

M.E. Dissertation by Rahul Tripathi

M.E. Dissertation by Rahul Tripathi

Fig. Sectional view of solar air heater

M.E. Dissertation by Rahul Tripathi

M.E. Dissertation by Rahul Tripathi

M.E. Dissertation by Rahul Tripathi

Assembly and Fabrication of the Experimental setup

Fig Wooden Frame of the solar air heater

M.E. Dissertation by Rahul Tripathi

M.E. Dissertation by Rahul Tripathi

M.E. Dissertation by Rahul Tripathi

M.E. Dissertation by Rahul Tripathi

Fig. .Final Assembly of transition piece and

Fig 3.25 mm thick Aluminium sheet