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Journal of Solar Energy Research Vol 4 No 1 (2019) 73-83

Journal of Solar Energy Research (JSER)

Journal
Journal
homepage:
homepage:
www.jser.ut.ac.ir
jser.ir

ClickPerformance
here, type the
Analysis
title of your
of Solar
paper,
Air Capitalize
Heater Having
first letter
Absorber
of each
Plate
words
Artificially Roughened by Chamfered-Square Elements
First Authora, Second Authorb,*
M. S. Azada*, A. Layekb
a
First affiliation, Address, City and Postcode, Country
b
a Second affiliation,
CSIR-Central Address,
Mechanical CityResearch
Engineering and Postcode, CountryIndia; *Email: [email protected]
Institute, Durgapur,
b
Mechanical Engineering Department, National Institute of Technology, Durgapur, India

ARTICLE
ARTICLEINFO
INFO A B S T R A C T
Received:
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revised
Marchform:
2019 A very common technique to improve the thermo hydraulic performance of solar air heater is
Accepted:
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Thermal performance
© 2019 Published byby
© 2013Published University ofof
University Tehran Press.
Tehran AllAll
Press. rights reserved.
rights reserved.

1. Introduction the heat transfer co efficient of a solar air heater

With rapidly growing population, (SAH) is very poor. Numerous techniques have so
industrialization, and transportation demand for far been used to improve the heat transfer rate and
energy is being continuously rising. The continuous the thermal efficiency of SAH. Some of these are,
use of limited stock of fossil fuels on the earth, felt use of fins [1-4] and packed bed [5], use of
energy starvation globally. The uncontrolled use of artificially roughened absorber plate [6-8] etc.
fossil fuel resulted serious environmental problem, Among these the easiest and the most acceptable
which forced the scientific community to think new method to enhance the thermal performance is the
and alternate ways to fulfil the future energy employ of artificially roughened absorber plate for
demand. The freely and abundantly available solar the solar air heater.
energy has capability to curb these energy demands The laminar sub-layer is formed on the
among the all sources of renewable energy. The conventional absorber plate, which is cause of
solar insolation gets absorbed by a absorber surface thermal resistance to heat transfer. To destroy the
of solar air heater and heat is transferred to the air laminar sub-layer, artificial roughness is employed
blowing under it. The hot air gets application in on absorber plate to improve the convective heat
space heating or process heating. The rate of heat transfer by creating turbulence in the flow. This led
transfer between the absorber plate and the blowing to increase in friction losses and to overcome from
air even for the turbulent flow is very low hence it more power is required by the fan or blower.
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Various researchers have investigated the thermo- study based on the CFD approach is proposed to
hydraulic performances of solar air heater investigate the effectiveness of the roughness
embedded with different types of artificial element for improved thermal performance of the
roughness elements with an emphasis on the effect heater.
of different roughness parameters. These are
comprehensively reviewed by Kumar et al. [8] and 2. Materials and Methods
not repeated here for the purpose of brevity. Diagonally chamfered square elements of 8 mm
Vyas and Shringi [9] performed CFD based to 14 mm arm length and 2 to 4 mm height have
analysis on the solar air heater having baffles as been used as artificial roughness elements and
roughness elements to investigate thermal inserted inner-side of the absorber plate. Various
performance and found 2.23 times more heat relative roughness pitches (transverse and
transfer compared to smooth plates. Vikrant et al. longitudinal) have been used for investigation. The
[10] investigated numerically the performance of hydraulic diameter (D) of SAH duct used for
solar air heater equipped with circular transverse investigation is 45 mm. A uniform heat flux of
wire ribs as roughness element and found 1000W/m2 has been applied on the absorber plate
considerable heat transfer enhancement. Prasad and for entire investigation. Reynolds number ranging
Saini[11] investigated the performance of solar air from (Re) 5000 to 22500, have been used for study
heater having small diameter wire as roughness to observe the effect of the roughness on nusselt
element and found considerable enhancement in number and friction factor as the SAH generally
Nusselt number and friction coefficient at relative operates at the same range.
roughness pitch of 10. Karwa et al. [12] The detail of the roughness is explained in Fig.
investigated V-discrete and V-continuous rib as 1. Remaining all three sides of test duct are
roughness element experimentally and reported that considered as smooth surfaces. A SAH duct having
discrete ribs and 60o ribs perform better than the dimensions as 2100mm long(L) , 200mm width(W)
continuous rib and 45o ribs respectively. Rasool et and 25 mm height(H) have been used for CFD
al. [13] ] performed CFD based numerical analysis analysis. The aspect ratio 8 was constant for entire
SAH with double-pass channels having variable rib study. The flow domain was divided in three
shapes and found boot shape ribs performing better sections i.e., entry section, entry section and test
then house shape and conventional square shape section. To minimise the end effects the entry
ribs. section (725mm) and exit section (325mm) of the
It is observed that majority of the works flow domain were kept sufficiently large.
available in the literature except a few are A secondary flow is assume to be happen as the
experimental. A numerical analysis can be used roughness geometry is inclined in the transverse
successfully as an alternative to the expensive direction of air flow, therefore a 3D flow domain
experimental investigation and in quick time have been selected for the study. ICEM CFD of
several different orientations can be studied for ANSYS 13.0 is used for meshing of domain in the
their effectiveness in order to improve the thermal present work [14]. Finer mesh in the rib region and
efficiency of SAH. Accordingly, a novel approach relatively coarser mesh for other region has been
is adopted here to use diagonally chamfered cuboid used for accurately examine the flow behaviour and
elements to be inserted artificially on the absorber heat transfer.
plate of the SAH for making it rough. A numerical

Figure 1. Detailed of the roughness elements

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The system of governing equation consists of absorber plate are adiabatic and the
the continuity, momentum and energy equations. working fluid air is incompressible for the
The governing equations for 3-D domain are
shown below:
test range of SAH. These assumptions
Continuity equation: were made based on the previous
investigations done by the researchers in
u v w their experiments. Table.1 shows the
  0 (1)
x y z thermophysical properties of air and
aluminum plate which are working fluid
Momentum equation: and absorber plate respectively.

u u u 1 p   2u  2u  2u  Table 1. Thermophysical properties of working

u v w        fluid and absorber plate.
x y z  x  x 2 y 2 z 2  Absorber
(2) Parameter Air plate
(aluminium)
v v v 1 p   v  v  v 
2 2 2
u v w         g  T  T  Specific heat (Cp,
1004.9 871.00
x y z  y  x2 y 2 z 2  J/kgK)
(3) Thermal conductivity
0.02624 202.40
(k, W/mK)
w w w 1 p   w  w  w 
2 2 2
u v w        Density (ρ, kg/m3) 1.225 2719.00
x y z  z  x 2 y 2 z 2 
1.846
(4) Viscosity (μ, N/m2) -
x105
Energy equation: Thermal expansion
0.0034 -
coefficient (β, K-1)
T T T  T  T  T 
2 2 2
u v w   2  2  2 
x y z  x y z  The boundary conditions of solution domain
were specified as, velocity inlet at inlet and outflow
(5) at outlet. The turbulence has been specified by
turbulence intensity and hydraulic diameter. The
where u, v, w are the components of the boundary condition applied at absorber plate was
fluid velocity in x, y and z directions of the constant heat flux. SIMPLE (semi-implicit method
for pressure linked equations) algorithm with
rectangular Cartesian coordinate, p is the second order upwind numerical scheme of the
pressure, T is the temperature and T ∞ is the governing equations has been used for the pressure-
ambient temperature. The thermo-physical velocity coupling.
properties are described through the
density (ρ), kinematic viscosity (ν), 3. Selection and Validation of Model
It is very essential to choose and validate the
thermal diffusivity (α = k/ρC p) with k best fitted turbulence model for computational
being the thermal conductivity and C p the analysis. For the smooth duct having same cross
specific heat at constant pressure, β is the section Dittus-Boelter empirical correlation [15] for
volumetric thermal expansion coefficient the Nusselt number and modified Blasius equation
and g is the acceleration due to gravity. for the friction factor have been compared with
various turbulence models such as Standard (STD)
In the present study of CFD analysis of k-ε model and Realizable (RLG) k-ε model.
SAH duct ANSYS FLUENT 13.0 has
been used as computational tool. A 3D Dittus-Boelter correlation for smooth duct:
model of computational domain has been Nu  0.024Re0.8 Pr 0.4 (6)
used due to presence of secondary flow in
transverse direction. A fully developed, Modified Blasius equation:
steady and turbulent flow is assumed. It is f s  0.085Re0.25 (7)
also assumed that all walls of duct except

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Figure 2. Variation of Nusselt number for different predicted turbulence models with the Dittus-Boelter relation for smooth
duct

Amongst the all predicted values the STD k-ε results which have been compared with various
turbulence model have been found best fitted with turbulence models for friction factor varying with
the Dittus-Boelter empirical correlation and the Reynolds number. The values found for STD k-ε
modified Blasius equation results. It is very clearly turbulence model are within 5% deviation from the
shown in, Fig.2 where Dittus-Boelter correlation predicted value from the Dittus-Boelter correlation
results have been compared with various and modified Blasius equation for the Nusselt
turbulence models for Nusselt number varying with number and friction factors respectively are within
Reynolds number for smooth duct. Similarly it is acceptable limit. Based on the validation results
shown in, Fig.3 for modified Blasius correlation STD k-ε turbulent model is selected for CFD
analysis of SAH duct to get best result.

Figure 3. Variation of friction factor for different predicted turbulence models with the modified Blasius relation for smooth
duct.

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of Nusselt number with respect to Reynolds
4. Results & Discussion number for different relative roughness pitch
(longitudinal pitch, Pa/e = 6, 7, 8 and transverse
All simulation results found for the roughened pitch, Pt/e = 4, 6, 7, 8), fixed element size and fixed
absorber plate are presented and compared with the relative roughness height of the roughness element
smooth plate result. The improvement in is shown in Fig.4. The variation of Nusselt number
thermohydraulic performance of the SAH for with respect to Reynolds number for different
variable flow rate is discussed below. element size having fixed longitudinal and
transverse relative roughness pitch (Pa/e = 7, Pt/e =
7) and fixed Relative roughness height is shown in
4.1. Heat Transfer
Fig.5. Similarly, The variation of Nusselt number
with respect to Reynolds number for different
Nusselt number is function of heat transfer and
relative roughness height having fixed element size
shows the thermal behaviour of the SAH. Fig.4, 5
and fixed longitudinal and transverse relative
and 6, shows that the Nusselt number is directly
roughness pitch (Pa/e = 6, Pt/e = 6) is shown in Fig.
dependent on Reynolds number as Nusselt number
6.
increases with increase in is Reynolds number for
roughened as well as smooth plate . The variation

Figure 4. Variation of Nusselt Number for different relative roughness pitches having fixed element size and fixed relative
roughness height.

It can be clearly observed from the above plots Friction factor affects the thermohydraulic
that increase in the relative roughness pitch, cross performance of SAH. The effect of roughness on
sectional area and relative roughness height, friction factor studied is shown in Fig.7, 8 and 9.
increases the value of Nusselt number. It can be The variation of friction factor with respect to
also observed that the Nusselt number increases Reynolds number for different relative roughness
substantially for the roughened plate in comparison pitch (longitudinal pitch, Pa/e = 6, 7, 8 and
to the smooth plate. Hence, the SAH embedded transverse pitch, Pt/e = 4, 6, 7, 8) fixed cross
with the artificial roughness element is found to be section of the roughness element (8×4: arm×height)
more effective in a sense that it provides enhanced and fixed relative roughness height is shown in
thermal performance. The highest Nusselt number Fig.7. The variation of friction factor with respect
is found as 84.3 at Pa/e = 7, Pt/e = 7 (with element to Reynolds number for different element size
cross section of 12×4). having fixed longitudinal and transverse relative
roughness pitch (Pa/e = 7, Pt/e = 7) and fixed
4.2. Friction Factor Relative roughness height is shown in Fig.8.

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Figure 5. Variation of Nusselt Number for different element size having fixed relative roughness pitch and fixed relative
roughness height.
Nusselt Number

Figure 6. Variation of Nusselt Number for different relative roughness height having fixed element size and fixed relative
roughness pitch.

Similarly, The variation of friction factor with friction factor decreases. This happens due to the
respect to Reynolds number for different relative suppression of laminar sub-layer for fully
roughness height having fixed element size and developed turbulent flow in the SAH duct. The
fixed longitudinal and transverse relative roughness maximum and minimum friction factor for the
pitch (Pa/e = 6, Pt/e = 6) is shown in Fig. 9. roughened absorber plate found is 0.0149 at Re =
It can be clearly observed from the above plots that 5000 for Pa/e = 7, Pt/e = 7 (with cross section 14×4)
with increase in Reynolds number the value of the and 0.00702 at Re = 22,500 for Pa/e = 7 and Pt/e =
7 (with cross section 8×2) respectively.

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Friction factor

Figure 7. Variation of friction factor for different relative roughness pitch having fixed element size and fixed relative
roughness height.
Friction factor

Reynolds Number

Figure 8. Variation of friction factor for different element size having fixed relative roughness pitch and fixed relative
roughness height.

4.2. Nusselt number enhancement ratio of the roughened absorber plate to that of the
The enhancement ratio of the Nusselt number is smooth absorber plate [13]and can be calculated as;
defined as the ratio of the Nusselt number obtained

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Friction factor

Reynolds Number

Figure 9. Variation of friction factor for different relative roughness height having fixed element size and fixed relative
roughness pitch
Nur/Nus

Reynolds Number
Figure 10. Variation of Enhancement ratio with respect to Reynolds number

least Reynolds number. The value of enhancement

Generally the entire configurations give ratio of Nusselt number decreases with increase in
significant enhancement in Nusselt number i, e Reynolds number for all sets of configurations
considered.
˃1 for the range of Reynolds number studied. Fig.
10 shows that enhancement ratio is 1.54 at Pa/e=7, 4.3. Friction factor ratio
Pt/e=7_14x4. Using the diagonally cut square Similarly, the friction factor ratio is defined as
element as roughness element an increase on 54% the ratio of the friction factor obtained of the
in Nusselt number is found. The maximum value of roughened absorber plate to that of the smooth
enhancement ratio of Nusselt number is found at
absorber plate [13] and can be calculated as;

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Similar to the enhancement ratio of the Nusselt cut square element as roughness element an
number, the friction factor ratio also gives greater increase in 40% in friction factor is found.
The maximum value of friction factor ratio is found
value for entire configurations i, e ˃1 for the
at least Reynolds number. The value of friction
range of Reynolds number studied. Fig. 11 shows factor ratio decreases with increase in Reynolds
that highest friction factor ratio is 1.4 at Pa/e=7, number for all sets of configurations studied.
Pt/e=7, cross section of 14x4. Using the diagonally
Frr/Frs

Reynolds Number

Figure 11. Variation of Friction factor ratio with respect to Reynolds number

4.4. Performance parameter studied roughness geometries is shown in Fig. 12.

The application of artificially roughened The Higher value of the performance parameter
absorber plate in the duct duct of SAH increases represents an appreciable performance of the SAH
the Nusselt number as well as the friction factor. duct. It can also be observed that for entire range of
The increase in friction in the flow region needed Reynolds number the value of the performance
more pumping power so that the air can be easily parameter is greater than unity. Furthermore, for
driven in the SAH duct. Accordingly, in order to all different types of roughness geometry except
predict the overall performance of the SAH, a Pa/e = 6 and Pt/e = 4 (with cross section 8×4), the
Performance parameter is defined as [16] value of performance parameter is highest at Re =
5000. Thereafter it decreases up to Re = 10000
Nur Nus sharply, and then there is a slight increase from Re
Performance parameter, ɳ  (8) = 12500 to 22500. The SAH gives the best
 fr fs 
13
performance for the roughness geometry Pa/e = 7
The variation of the performance parameter and Pt/e = 7 (with cross section 12×4).
with respected to Reynolds number for all the

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Performance parameter, ɳ

Reynolds Number
Figure 12. Variation of performance parameter with Reynolds number

5. Conclusions 7. decreases with increase in Reynolds number for

all sets of configurations.
This study presents a three-dimensional CFD 8. The highest value of friction factor ratio found is
analysis of the thermohydraulic performance of a 1.4 at least Reynolds number. The friction factor
rectangular duct SAH having roughened absorber ratio also decreases with increase in Reynolds
plate with chamfered square roughness elements. number for all sets of configurations.
The major findings of the study are itemized 9. The Roughness geometry with relative roughness
below: pitch (transverse and longitudinal) of 7, relative
1. The thermal performance of the SAH in presence roughness height of 0.088 mm and 12 mm cube
of the chamfered square roughness elements is arm is found to have the best performance
observed to be improved compare to the smooth parameter.
duct. The Nusselt number increases 1.23-1.54
times for the roughened heater compared to the Nomenclature
conventional ones for the range of Reynolds
L Solar air heater duct length, mm
number studied.
2. Increase in Nusselt number is found with H Solar air heater duct height, mm
increase in Reynolds number for the roughened W Solar air heater duct width , mm
absorber plate. The Nusselt number of the W/H Aspect ratio
roughened absorber plate is found in the range of D The hydraulic diameter of the duct, mm
21.32 - 84.3 W/m2K and for the smooth absorber e Roughness height of the element, mm
plate in range of 17.4-61.8 W/m2K. A Arm length of the roughness element, mm
3. Increase in friction factor is found for the e/D Relative roughness height
roughened absorber plate with campare to that of Re Reynolds number
the smooth absorber plate. The range of friction Pa/e Relative roughness pitch in longitudinal
factor found is 0.0070 - 0.0149 for the roughened direction, mm
plate, whereas 0.0066- 0.0106 for the smooth plate. Pt/e Relative roughness pitch in transverse
4. The increase in Reynolds number increases the direction, mm
Nusselt number whereas decreases the friction Nus Nusselt number of smooth duct
factor for all sets of combination of roughness Nur Nusselt number of roughened duct
parameters. Frs Friction factor for smooth duct
5. The highest value of enhancement ratio of Frr Friction factor for roughened duct
Nusselt number found is 1.54 at least Reynolds I Heat flux, W/m2
number. The enhancement ratio of Nusselt number
6.
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rectangular solar air heater duct having 60° inclined
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Heat transfer and friction factor correlations for
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