Article(id=1319294774788600284, tenantId=1146029695717560320, journalId=1316781260334530699, issueId=1319294714340291556, articleNumber=null, orderNo=null, doi=10.3969/j.issn.1005-0329.2025.11.010, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=null, receivedDate=1750694400000, receivedDateStr=2025-06-24, revisedDate=1760544000000, revisedDateStr=2025-10-16, acceptedDate=null, acceptedDateStr=null, onlineDate=1792473985620, onlineDateStr=2026-10-20, pubDate=1764432000000, pubDateStr=2025-11-30, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1792473985620, onlineIssueDateStr=2026-10-20, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1792473985620, creator=13701087609, updateTime=1792473985620, updator=13701087609, issue=Issue{id=1319294714340291556, tenantId=1146029695717560320, journalId=1316781260334530699, year='2025', volume='53', issue='11', pageStart='1', pageEnd='106', issueExtLink='null', onlineDate='null', pubDate='1764432000000', pubDateStr='2025-11-30', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1792473971208, creator='13701087609', updateTime=1792473971208, updator='13701087609', preIssue=null, nextIssue=null, articleTotal=null, ext=null, issueFiles=null, downloadFileDto=null}, startPage=75, endPage=83, ext={EN=ArticleExt(id=1319294774947983837, articleId=1319294774788600284, tenantId=1146029695717560320, journalId=1316781260334530699, language=EN, title=Study on flue gas condensation‑coupled heat transfer in bionic‑honeycomb twisted tube waste heat recovery unit, columnId=null, journalTitle=Fluid Machinery, columnName=null, runingTitle=null, highlight=null, articleAbstract=

To enhance the recovery and utilization efficiency of high‑temperature flue gas waste heat in natural gas heat treatment furnaces,an efficient bionic‑honeycomb twisted tube waste heat recovery unit is proposed to deeply recover waste heat from flue gas.The study designed a waste heat recovery unit consisting of nine bionic‑honeycomb twisted tubes and conducted numerical simulations of its condensation‑coupled heat transfer process using the CFD software Fluent.By varying the volume flow rates of combustion air and flue gas,the heat transfer and resistance characteristics of the bionic‑honeycomb twisted tubes were systematically analyzed.The results show that when the flue gas and combustion air volume flow rates are 0.889,0.978 m3/s,respectively,the system achieves optimal performance,cooling the 950 ℃ flue gas to 135 ℃ while heating the combustion air to 588 ℃.Under the operating condition with a Re of 6 860 and a water vapor content of 10%,the comprehensive heat transfer and economic performance of the recovery unit are optimal,with its performance evaluation index significantly improved by approximately 25% compared to conventional circular tube heat exchangers.Due to its unique structure,the bionic‑honeycomb twisted tube waste heat recovery unit achieves efficient energy recovery through enhanced heat transfer and can be universally applied to industrial furnace flue gas waste heat recovery,providing a reliable solution for industrial energy‑saving technological transformation.

, authors=Yong GAN, Haiting CUI, Yawei WANG, Jingru TIAN, Ning YAO, Yvxuan XIN, Haosong CHEN, authorsList=Yong GAN, Haiting CUI, Yawei WANG, Jingru TIAN, Ning YAO, Yvxuan XIN, Haosong CHEN, authorCompany=null, correspAuthors=Haiting CUI, authorNote=null, correspAuthorsNote=null, copyrightStatement=null, copyrightOwner=null, extLink=null, articleAbsUrl=null, sourceXml=null, magXml=null, pdfUrl=null, pdf=null, pdfFileSize=null, pdfExtLink=null, richHtmlUrl=null, mobilePdfUrl=null, reviewReport=null, pdfFirstPage=null, abstractGraph=null, abstractGraphContent=null, abstractVideo=null, citation=null, cebUrl=null, magXmlContent=null, mapNumber=null, fund=null), CN=ArticleExt(id=1319294778752217596, articleId=1319294774788600284, tenantId=1146029695717560320, journalId=1316781260334530699, language=CN, title=仿蜂巢扭管余热回收器烟气冷凝耦合传热研究, columnId=1317484287230853622, journalTitle=流体机械, columnName=设计计算, runingTitle=null, highlight=null, articleAbstract=

为提升天然气热处理炉高温烟气余热回收利用率,提出了一种高效的仿蜂巢扭管余热回收器,以深度回收烟气中的余热。研究设计了由9根仿蜂巢扭管组成的余热回收器,并利用CFD软件Fluent对其冷凝耦合传热过程进行数值模拟。通过改变助燃气与烟气的体积流量,系统分析了仿蜂巢扭管的传热与阻力特性。结果表明,当烟气和助燃气体积流量分别为0.889,0.978 m3/s时,系统性能最佳,能将950 ℃的烟气冷却至135 ℃,同时将助燃气加热至588 ℃;在雷诺数Re为6 860,且水蒸气含量为10%的工况下,该回收器综合传热经济性最优,其性能评价指标较常规圆管换热器显著提升,约25%。仿蜂巢扭管余热回收器因其独特结构,通过强化传热实现了能量的高效回收,能普适性地应用于工业炉窑烟气余热回收,为工业节能技术改造提供了可靠方案。

, authors=甘拥, 崔海亭, 王亚薇, 田景茹, 姚宁, 辛宇轩, 陈浩松, authorsList=甘拥, 崔海亭, 王亚薇, 田景茹, 姚宁, 辛宇轩, 陈浩松, authorCompany=null, correspAuthors=崔海亭, authorNote=

甘拥(1999),男,主要从事天然气热处理炉烟气余热回收研究,通信地址:050018河北省石家庄市裕华区裕翔街26号河北科技大学机械工程学院,E-mail:。

, correspAuthorsNote=
崔海亭(1964),男,教授,硕士生导师,主要从事新能源与强化传热技术方面研究,通信地址:050018河北省石家庄市裕华区裕翔街26号河北科技大学机械工程学院,E-mail:。
, copyrightStatement=作者向本刊所投稿件一经本刊录用,则该论文的复制权、发行权、信息网络传播权、翻译权、汇编权等权利视为自动转让给本刊。本刊为国内各主要数据库收录期刊,本刊所发表的稿件将同时通过互联网进行网络出版或提供信息服务。, copyrightOwner=null, extLink=null, articleAbsUrl=null, sourceXml=fQv1eGDScsz3jn2JQV6Qbg==, magXml=QwXQEBLX+5kk3T8dfCa7pw==, pdfUrl=null, pdf=null, pdfFileSize=null, pdfExtLink=null, richHtmlUrl=null, mobilePdfUrl=null, reviewReport=null, pdfFirstPage=null, abstractGraph=5+pZpyTOwnBMUWbQiqX/Yg==, abstractGraphContent=null, abstractVideo=null, citation=null, cebUrl=null, magXmlContent=bUV47uYB/86f/zQMydILOA==, mapNumber=null, fund=null)}, authors=[Author(id=1319294779041624577, tenantId=1146029695717560320, journalId=1316781260334530699, articleId=1319294774788600284, orderNo=0, firstName=null, middleName=null, lastName=null, nameCn=null, orcid=null, stid=null, country=null, authorPic=null, dead=0, email=1824658546@qq.com, emailSecond=null, emailThird=null, correspondingAuthor=0, authorType=1, ext={EN=AuthorExt(id=1319294779125510659, tenantId=1146029695717560320, journalId=1316781260334530699, articleId=1319294774788600284, authorId=1319294779041624577, language=EN, stringName=Yong GAN, firstName=Yong, middleName=null, lastName=GAN, prefix=null, suffix=null, authorComment=null, nameInitials=null, affiliation=null, department=null, xref=null, address=School of Mechanical Engineering,Hebei University of Science and Technology,Shijiazhuang 050018,China, bio=null, bioImg=null, bioContent=null, aboutCorrespAuthor=null), CN=AuthorExt(id=1319294779196813828, tenantId=1146029695717560320, journalId=1316781260334530699, articleId=1319294774788600284, authorId=1319294779041624577, language=CN, stringName=甘拥, firstName=null, middleName=null, lastName=null, prefix=null, suffix=null, authorComment=null, nameInitials=null, affiliation=null, department=null, xref=null, address=河北科技大学 机械工程学院,石家庄 050018, bio={"content":"

甘拥(1999),男,主要从事天然气热处理炉烟气余热回收研究,通信地址:050018河北省石家庄市裕华区裕翔街26号河北科技大学机械工程学院,E-mail:。

"}, bioImg=null, bioContent=

甘拥(1999),男,主要从事天然气热处理炉烟气余热回收研究,通信地址:050018河北省石家庄市裕华区裕翔街26号河北科技大学机械工程学院,E-mail:。

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Structural parameters of bionic‑honeycomb twisted tube waste heat recovery unit

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参数数值
烟气流入口直径/mm1 000
箱体尺寸/(mm×mm×mm)1 200×1 200×3 000
折流板尺寸/(mm×mm×mm)1 180×800×10
换热管长度/mm2 800
流体挡板尺寸/(mm×mm×mm)1 180×1 180×10
烟气流出口直径/mm1 000
助燃气流入口直径/mm500
助燃气流出口直径/mm500
), ArticleFig(id=1319294786603954762, tenantId=1146029695717560320, journalId=1316781260334530699, articleId=1319294774788600284, language=CN, label=表1, caption=

仿蜂巢扭管余热回收器结构参数

, figureFileSmall=null, figureFileBig=null, tableContent=
参数数值
烟气流入口直径/mm1 000
箱体尺寸/(mm×mm×mm)1 200×1 200×3 000
折流板尺寸/(mm×mm×mm)1 180×800×10
换热管长度/mm2 800
流体挡板尺寸/(mm×mm×mm)1 180×1 180×10
烟气流出口直径/mm1 000
助燃气流入口直径/mm500
助燃气流出口直径/mm500
), ArticleFig(id=1319294786679452235, tenantId=1146029695717560320, journalId=1316781260334530699, articleId=1319294774788600284, language=EN, label=Tab.2, caption=

Boundary conditions for numerical simulation

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边界边界类型参数数值
高温烟气进口速度入口流入速度/(m·s-1)0.3~2.0
温度/K1 223.15
水蒸气含量/%1~30
高温烟气出口出流边界流出速度/(m·s-1)—
温度/K—
助燃气
进口
速度入口流入速度/(m·s-1)1~9
温度/K298.15
助燃气
出口
出流边界流入速度/(m·s-1)—
温度/K—
), ArticleFig(id=1319294786746561100, tenantId=1146029695717560320, journalId=1316781260334530699, articleId=1319294774788600284, language=CN, label=表2, caption=

数值模拟边界条件

, figureFileSmall=null, figureFileBig=null, tableContent=
边界边界类型参数数值
高温烟气进口速度入口流入速度/(m·s-1)0.3~2.0
温度/K1 223.15
水蒸气含量/%1~30
高温烟气出口出流边界流出速度/(m·s-1)—
温度/K—
助燃气
进口
速度入口流入速度/(m·s-1)1~9
温度/K298.15
助燃气
出口
出流边界流入速度/(m·s-1)—
温度/K—
), ArticleFig(id=1319294786805281357, tenantId=1146029695717560320, journalId=1316781260334530699, articleId=1319294774788600284, language=EN, label=Tab.3, caption=

Outlet temperature under different combustion air flow rates

, figureFileSmall=null, figureFileBig=null, tableContent=
体积流量/(m3⋅s-1)高温烟气
出口温度/K
助燃气
出口温度/K
0.196883.3571 212.899
0.589506.4981 213.084
0.978408.739861.332
1.375339.451729.774
1.767299.015607.186
), ArticleFig(id=1319294786864001614, tenantId=1146029695717560320, journalId=1316781260334530699, articleId=1319294774788600284, language=CN, label=表3, caption=

不同助燃气流量下的出口温度

, figureFileSmall=null, figureFileBig=null, tableContent=
体积流量/(m3⋅s-1)高温烟气
出口温度/K
助燃气
出口温度/K
0.196883.3571 212.899
0.589506.4981 213.084
0.978408.739861.332
1.375339.451729.774
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仿蜂巢扭管余热回收器烟气冷凝耦合传热研究
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甘拥 , 崔海亭 , 王亚薇 , 田景茹 , 姚宁 , 辛宇轩 , 陈浩松
流体机械 | 设计计算 2025,53(11): 75-83
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流体机械 |设计计算 2025 , 53 (11) : 75 -83
仿蜂巢扭管余热回收器烟气冷凝耦合传热研究
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甘拥(1999),男,主要从事天然气热处理炉烟气余热回收研究,通信地址:050018河北省石家庄市裕华区裕翔街26号河北科技大学机械工程学院,E-mail:。

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甘拥(1999),男,主要从事天然气热处理炉烟气余热回收研究,通信地址:050018河北省石家庄市裕华区裕翔街26号河北科技大学机械工程学院,E-mail:。

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甘拥 , 崔海亭 , 王亚薇, 田景茹, 姚宁, 辛宇轩, 陈浩松
作者信息
  • 河北科技大学 机械工程学院,石家庄 050018
通讯作者:
崔海亭(1964),男,教授,硕士生导师,主要从事新能源与强化传热技术方面研究,通信地址:050018河北省石家庄市裕华区裕翔街26号河北科技大学机械工程学院,E-mail:。
作者简介:

甘拥(1999),男,主要从事天然气热处理炉烟气余热回收研究,通信地址:050018河北省石家庄市裕华区裕翔街26号河北科技大学机械工程学院,E-mail:。

Study on flue gas condensation‑coupled heat transfer in bionic‑honeycomb twisted tube waste heat recovery unit
Yong GAN , Haiting CUI , Yawei WANG, Jingru TIAN, Ning YAO, Yvxuan XIN, Haosong CHEN
Affiliations
  • School of Mechanical Engineering,Hebei University of Science and Technology,Shijiazhuang 050018,China
出版时间: 2025-11-30 doi: 10.3969/j.issn.1005-0329.2025.11.010
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为提升天然气热处理炉高温烟气余热回收利用率,提出了一种高效的仿蜂巢扭管余热回收器,以深度回收烟气中的余热。研究设计了由9根仿蜂巢扭管组成的余热回收器,并利用CFD软件Fluent对其冷凝耦合传热过程进行数值模拟。通过改变助燃气与烟气的体积流量,系统分析了仿蜂巢扭管的传热与阻力特性。结果表明,当烟气和助燃气体积流量分别为0.889,0.978 m3/s时,系统性能最佳,能将950 ℃的烟气冷却至135 ℃,同时将助燃气加热至588 ℃;在雷诺数Re为6 860,且水蒸气含量为10%的工况下,该回收器综合传热经济性最优,其性能评价指标较常规圆管换热器显著提升,约25%。仿蜂巢扭管余热回收器因其独特结构,通过强化传热实现了能量的高效回收,能普适性地应用于工业炉窑烟气余热回收,为工业节能技术改造提供了可靠方案。

工程传热传质学  /  烟气换热器  /  冷凝换热器  /  数值模拟

To enhance the recovery and utilization efficiency of high‑temperature flue gas waste heat in natural gas heat treatment furnaces,an efficient bionic‑honeycomb twisted tube waste heat recovery unit is proposed to deeply recover waste heat from flue gas.The study designed a waste heat recovery unit consisting of nine bionic‑honeycomb twisted tubes and conducted numerical simulations of its condensation‑coupled heat transfer process using the CFD software Fluent.By varying the volume flow rates of combustion air and flue gas,the heat transfer and resistance characteristics of the bionic‑honeycomb twisted tubes were systematically analyzed.The results show that when the flue gas and combustion air volume flow rates are 0.889,0.978 m3/s,respectively,the system achieves optimal performance,cooling the 950 ℃ flue gas to 135 ℃ while heating the combustion air to 588 ℃.Under the operating condition with a Re of 6 860 and a water vapor content of 10%,the comprehensive heat transfer and economic performance of the recovery unit are optimal,with its performance evaluation index significantly improved by approximately 25% compared to conventional circular tube heat exchangers.Due to its unique structure,the bionic‑honeycomb twisted tube waste heat recovery unit achieves efficient energy recovery through enhanced heat transfer and can be universally applied to industrial furnace flue gas waste heat recovery,providing a reliable solution for industrial energy‑saving technological transformation.

engineering heat and mass transfer  /  flue gas heat exchanger  /  condensation heat exchanger  /  numerical simulation
甘拥, 崔海亭, 王亚薇, 田景茹, 姚宁, 辛宇轩, 陈浩松. 仿蜂巢扭管余热回收器烟气冷凝耦合传热研究. 流体机械, 2025 , 53 (11) : 75 -83 . DOI: 10.3969/j.issn.1005-0329.2025.11.010
Yong GAN, Haiting CUI, Yawei WANG, Jingru TIAN, Ning YAO, Yvxuan XIN, Haosong CHEN. Study on flue gas condensation‑coupled heat transfer in bionic‑honeycomb twisted tube waste heat recovery unit[J]. Fluid Machinery, 2025 , 53 (11) : 75 -83 . DOI: 10.3969/j.issn.1005-0329.2025.11.010
天然气热处理炉作为金属材料加工的关键热工设备,在冶金、机械制造等行业应用广泛。其运行过程中产生大量高温烟气(通常可达600~1 000 °C)[1-3],蕴含着巨大的热能。然而,传统工艺设备中这部分高温烟气热量往往回收利用率较低,不仅造成显著的能源浪费,增加生产成本[4-6],还加剧了温室气体排放和热污染。
仿蜂巢状六边形结构在换热方面有着优异的性能,PATIL等[7]在圆管中加入六角环形湍流器,通过试验发现带有六角环形湍流器的管道在较高雷诺数下能实现最大传热速率,在较低雷诺数下实现最大传热率,分别是光管的3.01倍和32.7倍。圆管换热器会因使用环境的污染而劣化,相比之下,六边形管换热器通过在其表面分布污垢的梯度来减少腐蚀,其氧化和热腐蚀特性要优于圆管[8-9]。CAO等[10]通过CFD对带有翅片的不同边长比六边形管进行了研究,发现随着边长比的增加,其周围能产生更多的涡流使流体混合更充分。YADAV等[11]通过试验和CFD发现带有扭曲翅片的非圆截面管,随着边数的增加,其与传热效果相关的努塞尔数和摩擦系数也随之增加。然而MAHATO等[12-13]通过CFD发现,随着非圆截面管边数的增加,其管道截面会逐渐接近于圆形,会导致湍流强度减弱。KHAN等[14]在列管式换热器中引入直六角管代替圆管来增加流体接触面积,从而提高换热效率,通过CFD建立整个换热器的模型进行研究,得出了六边形几何形状增加了传热表面,从而提高了分子导热比例的结论。CHEN等[15-17]通过传热试验和CFD对扭曲非圆截面管传热性能进行了研究,并将非圆截面管中传热效果优异的扭曲六边形管应用于玉米秸秆浆余热回收,对比圆形直管沼气净产量可提高17%。
通过以上研究可以发现,在换热领域仿蜂巢状的六边形结构在非圆截面管中有较好的效果,已有许多关于六边形截面管和扭曲螺旋状管道在换热器方面的应用与研究[18-20],但像仿蜂巢扭管一样能将两种优异传热性能结合起来的研究相对较少。先前的研究中利用数值模拟软件Fluent,对单根不同截面扭管传热进行了数值模拟分析,并发现仿蜂巢扭管有较好的换热效果,现对由9根仿蜂巢扭管排列组合而成的列管式换热器对流冷凝耦合传热过程进行模拟研究,分析余热回收器中仿蜂巢扭管在不同工况下的传热和阻力特性,并探讨其因结构特性而较其他截面管更优的传热机理,为以天然气为燃料的热处理炉所排放高温烟气深度余热回收方面提供新方法。
仿蜂巢扭管余热回收器的结构如图1所示,其内部由9根仿蜂巢扭管按3×3矩阵排列构成。关键结构尺寸如下:两侧挡板与内壁面间距为100 mm;折流板与挡板间距为685 mm,折流板间距为790 mm;助燃气圆形入口与出口距两侧内壁面均为452.5 mm。单根仿蜂巢扭管的具体结构尺寸如图2所示,其管长L=2 800 mm,水力直径dh=200 mm,采用边长a=30 mm、壁厚δ=2 mm的不锈钢管制造,扭转匝数比S=0.5。其余结构参数见表1。
余热回收器物理模型由仿蜂巢扭管排列组合而成,可分为高温烟气区、壁厚区及助燃气区3个区域。高温烟气在管内流动,助燃气在管外与壳体间流动,二者采用逆流换热方式。为了简化计算,作出以下假设:
(1)忽略壁厚对传热与流动的影响;
(2)系统为绝热,不与外界发生能量交换。
数值模拟采用压力基求解器。压力-速度耦合使用SIMPLEC算法,压力插值格式为PRESTO。动量、能量与湍流方程均采用二阶QUICK格式进行离散。计算以残差降至10-6且进出口流量守恒为收敛标准[21]。管内介质为典型天然气燃烧烟气,其组分(体积分数)为71%N2,9%CO2,18%H2O与2%O2,工作压力为102 kPa,上述参数取自某厂热处理炉实际运行数据。烟气物性参数通过REFPROP获取,并在Fluent中以分段线性方式输入变物性数据。湍流模型选用RNG k-ε模型与增强壁面函数。助燃气与高温烟气入口设为速度入口,出口为出流边界。外管外壁绝热,内壁面设为流固耦合壁面[22]。具体边界参数见表2。
在Design Modeler中采用结构化网格对仿蜂巢扭管余热回收器进行划分。为精确捕捉近壁区流动与传热,在内外壁面流体交界处设置了边界层网格。壁面设为无滑移边界条件,并确保第一层网格的y+<1,网格高度按1.2的增长率进行设置。网格划分示意如图3所示。
采用RNG k-ε湍流模型进行数值计算,计算过程伴随相变的发生,设定烟气中水蒸气含量为0.01~0.25,且在干烟气中呈均匀分布而没有清晰的界面,因此采用混合(Mixture)模型[23],具体公式如下。
混合物连续性方程:
∂∂t(ρm)+∇⋅(ρmvm⃗)=0
混合物动量方程:
∂∂t(ρmvm⃗)+∇⋅(ρmvm⃗vm⃗)=-∇p+∇⋅[um(∇v⃗m+∇v⃗mT)]+ρmg⃗+F⃗   +∇⋅(Σk=1n=αkρkvd⃗r,kvd⃗r,k)
混合物能量方程:
∂∂t(ρnhm)+∇⋅[Σk=1n(αkρkvκ⃗hk)]=∇⋅(km∇T)+SE+∂p∂t+τm⋅∇vm⃗+Sh
式中,ρm为混合物密度,kg/m3;vm⃗为混合物速度,m/s;p为共享压力,Pa;um为混合物黏度,Pa·s;g⃗为重力加速度,m/s2;F⃗为其他体积力,N/m3;vd⃗r,k为第k相漂移速度,m/s。
根据蒸发冷凝的机理自行编写UDF程序[23],在蒸发冷凝的物理理论知识的基础上,经过不断的试验总结概括验证,得到蒸发冷凝模型如下式所示:
∂(αvρv)∂t+∇⋅(αvρvvV⃗)=m˙lv-m˙vl
式中,αv为流体中气相体积分数;ρv为气相密度,kg/m3;vV⃗为气相流动速度,m/s;m˙lv为液体转化为蒸汽的质量流量,kg/(m3·s);m˙vl为冷凝产生的液体的质量流量,kg/(m3·s)。
在余热回收器模拟中设置了与Z轴方向一致的重力加速度g。同时,为保证模拟过程中计算的一致性和准确性,所有参数均采用国际单位制。
余热回收器横截面上的主流温度Tf采用质量加权平均温度计算,其公式如下:
Tf=∫AuρCpTA/(∫AuρCpA)
余热回收器内高温烟气流动的局部传热系数hi和平均传热系数h为:
hi=qw/ (Tω,i-Tf,i)
h=∑i=1nhin,n=84
式中,u为速度,m/s;ρ为流体密度,kg/m3;Cp为定压比热容,J/(kg·K);qw为热流密度,W/m2;Tω,i为局部壁温,K;Tf,i为截面主流温度,K。
为进行网格无关性验证,在高温烟气和助燃气的体积流量分别为0.889,0.978 m3/s,温度分别为1 223.15,298.15 K工况下,监测了高温烟气出口温度随网格数量的变化,结果如图4所示。当网格数量从445万增至1 223万时,出口温度由391.69 K升至415.35 K。当网格数超过541万后,温度变化趋于平缓(401.03 K增至415.35 K),计算结果已基本不受网格数量影响。综合考虑计算精度与效率,最终选取541万网格进行模拟。
为验证数值模型的准确性,研究参照文献[15]的封闭传热试验,对单根仿蜂巢扭管设置了与之一致的物理模型与模拟环境。关键几何参数为:水力直径51 mm;壳体内径60 mm;管长1 000 mm;扭转比0.5。管侧冷流体速度(1.15~2.50 m/s)与壳侧热流体条件(70 ℃,1.5 m/s)均与文献工况保持一致,壁面设为绝热。
图5示出换热系数K随管侧流速U的变化趋势,与文献结论一致。对比分析可见,模拟与文献试验值的偏差均值为6%,和文献模拟与试验值的偏差(7.5%)接近。根据相关标准,CFD模拟与试验偏差低于10%,即可认为结果可靠[24-25]。因此,验证了本次数值计算方案、步骤及数学模型选择的正确性。
图6、图7分别示出高温烟气和助燃气体积流量为0.889,0.978 m3/s,温度为1 223.15,298.15 K的边界条件下,仿蜂巢扭管余热回收器在管道处及管道间y轴纵截面的温度分布云图。
由图6可以看出,仿蜂巢扭管组成的换热器温度分布均匀,换热效果优异。这得益于其独特的结构,六边形截面能在管壁处产生比四边形管更强且更连续的近壁剪切效应,同时引起的径向流混合又比更接近圆形的八边形管更强[15]。这种协同作用显著增强了湍流,有效破坏热边界层,从而强化了从高温烟气到助燃气的热量传递,最终实现了烟气出口温度更低而助燃气出口温度更高的换热效果。
图8示出余热回收器沿管长方向的速度流线图。可以看出,管内烟气与管外助燃气均呈现出清晰的螺旋状流动趋势,这是仿蜂巢扭管结构促进流体径向混合与增强壁面剪切效应的直观体现,有效地破坏了热边界层。沿流动方向,烟气速度呈现先减小后增大的变化规律。在入口段(1.0~0.8 m),因刚流入管内的高温烟气与助燃气温差大、换热剧烈,导致速度较高;在中间段(0.8~2.0 m),温差平缓,换热均匀,速度流线分布均匀;在接近助燃气入口段(约2.8 m处),与不断流入的低温助燃气相遇再次形成巨大温差,对流增强,导致速度显著上升。管外助燃气的速度变化规律与管内烟气相似,其速度峰值同样出现在温差最大的换热器两端。
图9中,沿管长方向的湍动能变化曲线呈先增后减再增的趋势,与图8中的速度流线规律一致。在高温烟气入口与助燃气出口区域,因流体温差较大,对流换热剧烈,故湍动能较高。在0.8~2.0 m的中间段,流体进行充分换热,温差平缓,流动相对稳定,湍动能显著降低。在高温烟气出口与助燃气入口区域,高温烟气与不断流入的低温助燃气再次形成巨大温差,强烈的对流运动致使湍动能快速回升。
为探究助燃气体积流量对仿蜂巢扭管内高温烟气流动与换热特性的影响,对其进行传热模拟。高温烟气入口温度、体积流量及水蒸气含量分别设为1 223.15 K,0.889 m3/s和10%,助燃气入口温度为298.15 K。通过改变助燃气体积流量(0.196,0.589,0.978,1.375,1.767 m3/s),分析了不同工况下的传热性能。沿换热器管长方向设置多个纵截面,经面积加权平均处理,得到能体现高温烟气主流温度与传热系数沿管长变化的曲线。
不同助燃气流量下的轴向温度分布如图10所示。从图可见,不同助燃气流量下,高温烟气温度均沿管长方向逐渐降低。在较低体积流量工况(0.196,0.589 m3/s)下,烟气温度下降幅度小,曲线整体较缓,仅在助燃气入口附近出现明显温降。这主要是由于助燃气流速较低,流经余热回收器时不能很好地带走高温烟气中所携带的热量所致。
不同助燃气流量下的出口温度见表3。可以看出,当助燃气体积流量速度较小(0.196,0.589 m3/s)时,助燃气吸收热量更充分,出口温度也较高,但高温烟气在出口处温度也较高,说明烟气中仍有大量热未被回收;当体积流量为0.978 m3/s时,烟气与助燃气流速相当,换热时间相对更充分,烟气出口温度显著降至408.7 K,同时助燃气被加热至861.3 K,实现了高效换热;当体积流量较大(1.375,1.767 m3/s)时,随着流量增加,助燃气停留时间缩短,出口温度明显降低。
虽然烟气出口温度进一步下降,但整体换热效率减弱,尤其在体积流量为1.767 m3/s时,由于助燃气流速过快,在低温助燃气入口附近温差较大,形成强烈局部换热,导致烟气温度快速下降,随后因温度低于周围环境而在出口段产生轻微的温度回升现象。
传热系数随助燃气流量的变化情况如图11所示。
从图可见,不同助燃气体积流量下,沿管长方向的传热系数均呈先快速升高再降低到一定范围浮动,最后又回升的趋势。该变化规律主要与逆流布置下两端入口区域流体温差大、换热强度高相关,这与图8中速度流线的规律一致。在高温烟气入口段(约0.4 m处),因冷热流体温差最大,传热系数急剧上升;在换热器中段,流体温差过渡较为平缓,传热系数在一定范围内波动;在助燃气入口附近,流体温差再次增大,传热系数相应出现回升。
比较不同流量工况可知,当助燃气体积流量为0.978 m3/s(与高温烟气流速相近)时,流体间换热时间较为充分,传热系数曲线整体高于其他工况;而流量过低或过高均会因换热时间不足导致传热效果下降。
对余热回收器中仿蜂巢扭管内高温烟气与助燃气对流冷凝耦合传热与阻力特性进行了研究。对位于余热回收器中的仿蜂巢扭管,除了关注传统的对流冷凝耦合传热努塞尔数Nu,还定义了冷凝当量努塞尔数Nucond,以表征耦合换热过程中潜热换热的效果[23],Nucond通过下式进行计算:
Nucond=hconddeλ
hcond=QcondAΔT
式中,hcond为管程冷凝当量传热系数,W/(m2·K);de为余热回收器中仿蜂巢扭管当量直径,m;λ为天然气热处理炉烟气的导热系数,W/(m·K);Qcond为冷凝潜热量,J/kg;A为换热表面积,m2;ΔT为对流传热温差,K。
仿蜂巢扭管管程Nu和Nucond随雷诺数增加的曲线变化如图12所示。从图可以看出,随着Re增加,仿蜂巢扭管与普通圆管的Nu及Nucond均呈现先增后缓的趋势,且前者的数值整体约为后者的2倍。这表明,在一定范围内,提高Re能有效强化烟气的显热与潜热交换;但当Re超过某一临界值后,其强化作用减弱,Nu与Nucond的变化不再显著。
仿蜂巢扭管和普通圆管的摩擦因数f及综合性能评价因子η随雷诺数Re的变化如图13所示。随着Re增加,摩擦因数f逐渐下降并最终趋于平缓。这是因为过度增强的湍流虽使近壁区速度梯度增大,但其引发的核心区剧烈动量混合使速度分布更均匀,反而削弱了壁面剪切应力的增长,导致f在高Re下趋于平缓。
强化传热效果的经济性分析可以通过综合性能评价因子η来体现,其计算式如下:
η=Nu/Nu0(f /f0)1/3
式中,Nu和Nu0分别为仿蜂巢扭管余热回收器和圆管冷凝换热器努塞尔系数;f和f0分别为仿蜂巢扭管余热回收器和圆管冷凝换热器摩擦系数。
综合性能评价因子η在图13中随雷诺数Re的增加呈先增大后减小的趋势,并逐渐小于1,表明过高的Re会削弱仿蜂巢扭管在余热回收中的经济性,评价因子η最大值2.3所对应雷诺数为6 860。
如图14所示,水蒸气含量增加对仿蜂巢扭管Nu和Nucond的影响变化曲线都呈先上升后趋于平缓的趋势,且仿蜂巢扭管的Nu和Nucond平均值分别为普通圆管的2.9倍与3.3倍。这表明适度增加水蒸气含量有助于显热和潜热的交换,但超过一定范围后,其强化效果逐渐减弱,Nu和Nucond变化也随之趋于平缓。
图15示出水蒸气含量对摩擦因数f与综合评价因子η的影响曲线,可以看出,随着水蒸气含量的增加,两种管型的摩擦因数均逐渐下降并最终趋于平缓,但仿蜂巢扭管的f平均值始终约为圆管的2.0倍。这表明,适度增加水蒸气含量有助于降低流动阻力,但超过一定范围后其影响减弱。当水蒸气含量为10%时,综合评价因子η达到最高值3.1。
(1)对由仿蜂巢扭管组成的余热回收器进行数值模拟,结果表明,仿蜂巢扭管因其特殊的曲面螺旋结构,能显著增强流体的径向混合与近壁区剪切效应,有效破坏热边界层,并结合折流板作用实现充分换热。
(2)改变边界条件模拟并观察不同工况下仿蜂巢扭管余热回收器传热特性,发现当高温烟气与助燃气的流速相当时(0.889,0.978 m3/s),余热回收效果最优,烟气温度可从950 ℃降至135 ℃,同时助燃气被加热至588 ℃。流速过高则会导致换热时间不足,回收效率下降。
(3)雷诺数与水蒸气含量的增加在一定范围内能强化显热与潜热交换,但超过临界值后强化效果减弱。在Re=6 860且水蒸气含量为10%的工况下,仿蜂巢扭管展现出最优的综合传热经济性,性能显著优于常规圆管。

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doi: 10.3969/j.issn.1005-0329.2025.11.010
  • 接收时间:2025-06-24
  • 首发时间:2026-10-20
  • 出版时间:2025-11-30
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  • 收稿日期:2025-06-24
  • 修回日期:2025-10-16
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    河北科技大学 机械工程学院,石家庄 050018

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崔海亭(1964),男,教授,硕士生导师,主要从事新能源与强化传热技术方面研究,通信地址:050018河北省石家庄市裕华区裕翔街26号河北科技大学机械工程学院,E-mail:。
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2种不同金属材料的力学参数
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鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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