Applied Energy: Gerd Schmid, Zun-Long Huang, Tai-Her Yang, Sih-Li Chen
Applied Energy: Gerd Schmid, Zun-Long Huang, Tai-Her Yang, Sih-Li Chen
Applied Energy
journal homepage: www.elsevier.com/locate/apenergy
h i g h l i g h t s g r a p h i c a l a b s t r a c t
a r t i c l e i n f o a b s t r a c t
Article history: The present study examines the use of a vertical double-pipe single-flow heat exchanger as part of an
Received 28 October 2016 active air cooling system for a 150 W LED street light. The air is circulated inside the lamppost by an inter-
Received in revised form 19 January 2017 nal fan to form a closed-loop system. The heat is dissipated to the surrounding air by natural convection,
Accepted 10 March 2017
reaching Rayleigh numbers up to Ra = 6.5 1010. Experiments with a 5 m high prototype were conducted,
Available online xxxx
and the data were used to validate the numerical model. The experimental results show that the LED
excess temperature can be lowered to about 42 C. A two-dimensional axisymmetric numerical simula-
Keywords:
tion was performed to study the influence of various parameters, including pipe length, material conduc-
Forced-air cooling system
Light emitting diode
tivity, flow direction, pipe diameter ratio, and mass flow rate, on the heat transfer rate. The findings show
Double-pipe heat exchanger that the additional heat loss created by extending the lamppost largely depends on the flow rate. When
Street light extending the lamppost from 3 to 5 m at a high mass flow rate of 0.014 kg/s, the heat loss increases by
Axisymmetric simulation 34.1% to 120.2 W. The numerical study was also used to visualize the hydrodynamic boundary layers
on the surface of the lamppost and the temperature contours in and outside of the heat exchanger.
2017 Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.apenergy.2017.03.054
0306-2619/ 2017 Elsevier Ltd. All rights reserved.
G. Schmid et al. / Applied Energy 195 (2017) 426438 427
Nomenclature
LED [2]. The maximum allowable junction temperature (Tj) for safe axial fans, which were arranged on top of a heat sink inside an alu-
operation varies among manufacturers, but is in the range of 120 minum housing, from which the heat is dissipated by natural con-
140 C. However, lower temperatures are desirable because they vection to the surroundings. Their results showed that the cooling
severely influence the lifespan of LEDs, as an increase in Tj of 10 system can reduce the temperature of a 68 W LED by up to 27.9 C,
15 C can reduce the lifetime by 50% [3]. compared to a case with only the heat sink. The main drawback of
Most studies on thermal management of LEDs have focused on this design is that the hot internal air is contained inside the hous-
the design and optimization of passive heat sinks [48], which are ing and only the lamp head case acts as an external cooling body.
often combined with heat pipes [911] or vapor chambers [12,13] Liquid cooling systems are more complex than forced air cooling
to improve the thermal performance by reducing the spreading systems, but they can provide higher cooling capacities. They usu-
resistance. Two recent studies found that perforations [8] or open- ally consist of a cold plate attached to the LED, a reservoir to store
ing slits [5] on the base of free-hanging oversized heat sinks can the liquid, a pump to drive it, and a liquid-to-air heat exchanger to
increase the air flow through the fin array and reduce the thermal dissipate the heat to the surroundings. Ramos-Alvarado et al.
resistance by up to 30.5% and 36.7%, respectively. Ye et al. [10] numerically compared multiple cold plates with different micro-
designed a heat sink with parallel vertical fins and three embedded channel designs [23] and, in a subsequent study, applied the best
heat pipes for high-power LED applications. Experimental and cold plate design to an array of 64 high-power LEDs with various
numerical analyses were carried out to investigate the optimal power inputs and flow rates [20]. Their simulations showed a Tj
fin spacing to achieve the smallest thermal resistance. The experi- of about 80 C at a total input power of 192 W and a pumping
ments with an 80 W LED showed that the optimized design can power of 1 W. However, the study considered an array of individ-
limit the temperature of the heat sink base to about 70 C. While ual LEDs instead of single high-power LED chip, and the pumping
passive cooling systems are extremely reliable and do not require power of 1 W is only derived from the numerical pressure drop
additional power consumption, they are usually limited to power across the cold plate and does not represent the complete cooling
inputs of less than 100 W. Active cooling solutions, such as forced system.
air [1419] or liquid cooling systems [2022], are more capable of The present study analyzes a novel forced-air cooling system for
maintaining the junction temperature of high-power LEDs under a LED street lights, which uses the lamppost as an air-to-air heat
critical limit. Deng et al. [14] conducted an experimental evalua- exchanger to dissipate heat to the surrounding air. The air-flow
tion of single-and dual-synthetic jet actuators combined with a inside the lamppost is driven by an internal fan, and the whole sys-
heat sink. The system consumed about 3.2 W of power and was tem is sealed to prevent dust and debris from entering the system;
used to cool a 30 W LED chip. The results showed that the this reduces maintenance cycles, lowers the risk of system failure,
single-synthetic jet actuator could maintain the base temperature and thus makes it especially suitable for extreme climatic condi-
at 46.5 C and the double jet could reduce it by 4 C. Synthetic jets tions. This type of vertical single-flow double-pipe heat exchanger
can be integrated in very compact systems, but for higher power has a similar working principle to coaxial ground heat exchangers
ranges, fans have a better overall heat dissipation capability. Geis- (GHEs) [2429]. However, the aim is not to transfer the heat from
ler [15] developed an active thermal solution consisting of multiple one pipe to the other, as in conventional double-pipe heat
fans combined with a densely folded copper heat sink. His design exchangers with two inlets and outlets [30], but rather to transfer
could maintain a dummy heater with a 600 W input at a base it through the outer pipe wall to the surrounding air. According to
excess temperature over ambient of 85 C. Iaronka et al. [16] the experimental findings of Jalaluddin et al. [24], coaxial GHEs
designed and investigated a closed-loop forced air cooling system have a 61% higher heat exchange rate than U-tube GHEs at a depth
for high-power LED street lamps. The system was driven by five of 20 m and a flow rate of 4 l/min. In fact, Acuna and Palm [27]
428 G. Schmid et al. / Applied Energy 195 (2017) 426438
2. Experimental method
Table 1
Material properties from the lamppost analysis (25 C) [34].
Table 2
Flow conditions for internal pipe with smooth surface.
3. Numerical method
This numerical study focuses on the heat loss from the lamp-
post to the surrounding air (dotted area in Fig. 1(c)). The lamppost
can be described as a vertical double-pipe single-flow heat exchan-
ger with natural convection to the surrounding air. The cross-
section of the lamppost is circular, and the heat loss to the sur-
rounding air is assumed uniform; hence, the flow is modeled as
axisymmetric with a rectangular two-dimensional domain, as
shown in Fig. 5(a). This simplification reduces the time taken for
the simulations by several orders of magnitude. According to
[37], turbulent flows are intrinsically three-dimensional because
certain mechanisms, such as vortex stretching or tilting, cannot
occur in two dimensions; nevertheless, they can still be two-
dimensional in a statistical sense. The geometry was thus drawn
as a two-dimensional line model consisting of four separate zones:
two solid regions for the internal pipe and the lamppost, and two
fluid regions, one inside the lamppost and the other representing
the surrounding air, as indicated in Fig. 5(b) and (c). The interfaces
between these fluid and solid zones are modeled as coupled walls,
which enable an accurate simulation of the real heat transfer
through those boundaries [38]. The grid is structured, built up from
quadrilateral elements, and aligned with the flow direction. The
grid cells are very dense close to the pipe walls to accurately model
the boundary layers.
Fig. 5. (a) Axisymmetric section of lamppost, (b) detail view of computational model with different domains, (c) full 2D-model showing mesh and boundary conditions.
model. These are all two-equation models based on the Reynolds- 3.3. Governing equations and boundary conditions
averaged Navier-Stokes (RANS) method, where the turbulent fluc-
tuations are averaged over time [37]. The theoretical background The governing equations for continuity, momentum, and energy
of the turbulence models can be found in [38]. Fig. 6 presents the conservation together with the realizable k-e turbulence model can
comparison results of the turbulence models. All design points be expressed as follows [37,42]:
reach Rayleigh numbers of over 1010, which are considered to be Continuity equation
fully turbulent [39]. The results of both k-e models are almost iden-
@ui
tical, showing very good agreement with the turbulent correlation 0 9
@xi
by Kreith et al. (Eq. (8)). These two turbulence models characterize
the turbulent field in terms of turbulent kinetic energy (k) and the Momentum equation
viscous dissipation rate (e). However, the standard k-e model is
@ui uj 1 @p @ @uj @ui
only valid for fully turbulent flows, which is not the case in the pre- m mt 10
@xi q @xi @xj @xi @xj
sent study [41]. The realizable k-e model was thus chosen for the
present simulations. Energy equation
@ui T @ m mt @T
11
@xi @xi Pr Prt @xi
Turbulent kinetic energy k equation
@ui k @ mt @k
m Ce 12
@xi @xi rk @xi
Turbulent energy dissipation e equation
@ui e @ mt @ e e2
m c1 Ce c2 13
@xi @xi re @xi k
with C being the generation of k given by
@ui @uj @ui
C mt 14
@xj @xi @xi
and mt is calculated as
2
k
mt 15
Fig. 6. Comparison of turbulence models applied to the lamppost simulation. e
432 G. Schmid et al. / Applied Energy 195 (2017) 426438
The empirical constants in Eqs. (12) and (13) were assigned as the pipe surface. Following the validation, the numerical models
[38]: c1 = max[0.43, l/(lt + 5)], c2 = 1.9, rk = 1.0, re = 1.2. The were used to study how various design parameters affect the ther-
enhanced wall treatment is used at the near-wall. Fig. 5 mal performance.
(b) and (c) shows the boundary conditions including the axis, a
mass flow inlet, pressure outlets (at the exit of the lamppost and 4.1. Experimental LED temperatures
at the boundaries of the ambient region), and wall boundaries with
zero heat flux at the top and bottom of the lamppost. A uniform Figs. 7 and 8 show the experimental results of the active cooling
temperature and a mass flow normal to the boundary with a turbu- system for different flow directions and pipe materials. In Fig. 7,
lent intensity of 1% were defined at the inlet. The gauge pressure at the excess temperatures (Tex = TLED Ta) of the LED are compared
the pressure outlets were set to the static pressure of the environ- for different volume flows ranging from 1.5 to 8.5 m3/s. Overall,
ment. The back flow conditions at the boundaries of the ambient it can be seen that the CISE flow leads to a slightly lower excess
region were assumed as 0.1% turbulence with a length scale of temperature than the SICE flow for both pipe materials. A compar-
0.1 m. The backflow at the outlet of the pipe was set to 323 K, ison of the results for the PVC and Al pipes shows that the pipe
and 1% turbulence with the corresponding hydraulic diameter of material has only a very small influence on the excess temperature.
0.0275 m. However, the PVC seems to have a marginally better thermal per-
formance. The lowest excess temperature of Tex = 44.2 C could be
3.4. Numerical setup achieved at V_ = 0.0072 m3/s with CISE and the PVC pipe. At low vol-
ume flows, under 0.002 m3/s, the excess temperature rose to
The simulation was carried out using the software ANSYS Fluent almost 60 C, and when the active cooling system was turned off
14.5. The solver was set to pressure-based, steady-state flow, and completely, an excess temperature of Tex = 72.3 C was measured.
absolute velocity formulation. The material properties were taken In Fig. 8, the experimental results are compared for different fan
as equal to those in the experimental analysis, listed in Table 1. power inputs ranging from 8 W to 20 W. When the fan power was
The Boussinesq model, which assumes that the density is constant reduced by 25% from 20 W to 15 W, the excess temperature
in all solved equations except for the body force term in the increased on average by only 1.5 C. Further reductions to 12, 10,
momentum equation, was chosen for the air density. The SIMPLEC and 8 W led to average increases of 2.3, 4.4, and 4.3 C, respec-
pressure-velocity coupling scheme was used and the gradient tively. These findings show that it is necessary to find a balance
option was set to least square cell based. For better accuracy, the between the thermal performance and power consumption, which
spatial discretization for momentum, the turbulent kinetic energy, depends on the design parameters and the equipment used.
and the turbulent dissipation rate and energy were all set to sec-
ond order upwind. The convergence criterion for the residuals of 4.2. Validation of numerical model
the governing equations was set to 105.
Figs. 9 and 10 show the direct comparisons of the experimental
and numerical results. The experiments were conducted for both
3.5. Grid independence study
flow directions and for two different internal pipe materials (Al
and PVC). Each numerical simulation used the same mass flow rate
A grid independence study was conducted to confirm that the
mesh density is high enough to capture all of the relevant features.
Table 3 summarizes the results of the grid independence study.
First, an initial grid with 28,390 elements was defined, and the
influence of grid refinements at various boundaries was then
checked. The surface-averaged temperature at the outlet (Tout)
and the heat loss to the surrounding air (Q_ ) were the monitored
parameters. The grid was finer adjacent to the walls to resolve
the boundary layer flow. The number of nodes in y-direction of
both solid regions (internal and outer post) was kept constant at
four. The analysis showed that the initial grid was sufficiently
accurate, because further refinements brought no significant
changes; the initial grid was therefore chosen for the numerical
analysis.
This section first presents the experimental results for the com-
plete lamppost, which were then used to validate the numerical
model by comparing the temperatures at the flow outlet and on Fig. 7. Experimental excess temperatures at different volume flows.
Table 3
_ = 0.014 kg/s).
Grid independence for lamppost simulation (Tin = 333 K, Ta = 303 K, m
# Mesh elements y-nodes inner pipe y-nodes outer pipe y-nodes ambient x-nodes total Tout (K) Q_ (W)
1 28,390 40 50 70 171 326.44 90.60
2 29,410 50 50 70 171 326.45 90.50
3 29,410 40 60 70 171 326.43 90.68
4 32,810 40 50 100 171 326.45 90.47
5 39,120 40 50 70 241 326.43 90.67
6 50,530 40 50 70 311 326.43 90.72
G. Schmid et al. / Applied Energy 195 (2017) 426438 433
Fig. 8. Experimental excess temperatures for different fan power inputs. Fig. 11. Heat loss over mass flow rate for different flow directions and pipe
materials (Ta = 303 K, Tin = 333 K).
Fig. 9. Comparison of outlet temperatures between the experiment and the Fig. 11 shows the influence of the flow direction (CISE vs. SICE)
simulation. and the material of the center pipe on the heat loss for mass flow
rates ranging from 0.002 to 0.014 kg/s. Materials with lower ther-
mal conductivity can reduce the thermal contact between the
down and up streaming air flow. Besides PVC and Al, which were
also tested experimentally, the simulation included a pipe made
of fiberglass (Fg) with an extremely small conductivity of
k = 0.04 W/m2 K. The fiberglass pipe displays a very small improve-
ment compared to the PVC pipe, of 2.1% and 1.5% over the mea-
sured temperature range for CISE and SICE, respectively, and the
difference between the Al and PVC pipes is less than 0.5% for both
flow directions. Hence, it can be concluded that the thermal con-
ductivity has only a small influence on the overall heat loss of
the present configuration. However, the flow direction clearly
affects the rate of heat loss. On average, the CISE flow direction
has an 11.4% higher heat loss than SICE for all three considered
materials.
Fig. 12 illustrates the influence of the inlet temperature on the
rate of heat loss for different mass flow rates. The inlet tempera-
ture was varied in steps of 10 K ranging from 313 to 353 K, while
the ambient temperature was kept constant at 303 K. For higher
inlet temperatures, the rate of heat loss increases linearly, with
higher slopes for higher velocities. The increase in the heat loss rate
is significant when the flow rate is changed from 0.002 to 0.004 kg/
Fig. 10. Comparison of the average pipe surface temperature between the s, but is much smaller when the flow rate is changed from 0.01 to
experiment and the simulation. 0.014 kg/s. Changing the inlet temperature increases the heat loss
434 G. Schmid et al. / Applied Energy 195 (2017) 426438
Table 4
Heat loss rates per unit length.
_ (kg/s)
m 0.002 0.006 0.01 0.014
(W/m) (CISE)
Q 1.81 8.15 12.58 15.73
(W/m) (SICE)
Q 2.65 9.95 14.27 17.14
small area ratios lead to high pressure drops and should be avoided
[26]. Fig. 14 shows the influence of the pipe area ratio on the heat
loss for different mass flow rates. Increasing the area ratio from
0.16 to 0.54 can slightly increase the overall heat transfer for both
flow directions. A further increase from 0.54 to 1.0 can enhance the
SICE flow but has no effect on the CISE flow. For the SICE configu-
ration, the maximum increase is up to 12.4% at the highest mass
flow rate of 0.014 kg/s, while the CISE flow only increases by
4.8% at the same mass flow rate. The influence of the pipe area ratio
is negligible for low mass flow rates of m_ = 0.002 kg/s.
Fig. 12. Influence of inlet temperature on heat transfer (Ta = 303 K, PVC pipe, CISE).
Table 5
Pipe ratios of lamppost and internal pipe.
Di (cm) Do (cm) Di/Do Inner pipe cross section Aip (cm2) Outer pipe cross section Aop (cm2) Aip/Aop
3.5 9.7 0.36 9.62 60.04 0.16
4.5 9.7 0.46 15.90 52.66 0.30
5.5 9.7 0.57 23.76 43.71 0.54
6.5 9.7 0.67 33.18 33.18 1.00
Fig. 14. Influence of the pipe ratio on the rate of heat loss (PVC pipe). Fig. 16. Heat loss for different ratios of dFC/dop.
the outer pipe surface of the lamppost. The thickness of the bound- The flow velocities and the shape of the boundary layers are very
ary layer is shown via isolines for velocities of 0.010.2 m/s, and similar for both flow directions on the upper part of the lamppost.
the flow on the pipe surface reaches velocities of over 0.4 m/s. However, on the lower part, the fan chamber clearly influences the
shape of the boundary layer depending on the flow direction
Fig. 18 shows the temperature contours inside the lamppost
and the distinguished thermal boundary layer for different config-
urations (scaled by 200% in radial direction). For the SICE flow
(Fig. 18(a) and (c)), a considerable amount of air is cornered at
the bottom of the fan chamber and does not take part in the flow
circulation; this becomes especially apparent at small mass flow
rates and is not desired, because it reduces the effective heat trans-
fer surface, which lowers the thermal performance. This phe-
nomenon also explains the sharp temperature drops at the
centerlines previously observed in Fig. 15(b) and (d). A possible
solution to this issue is to reduce the distance between the lower
exit of the internal pipe and the bottom of the fan chamber.
5. Conclusion
Fig. 18. Temperature contours in and around the lamppost for different flow
1. Experiments and simulations have shown that more heat can be
conditions (scaled by 200% in radial direction): (a) SICE at m_ = 0.002 kg/s, (b) CISE at dissipated from the lamppost when the air flows down the cen-
m_ = 0.002 kg/s, (c) SICE at m
_ = 0.014 kg/s, (d) CISE at m
_ = 0.014 kg/s. ter pipe and back up via the outer pipe (CISE). The increase in
G. Schmid et al. / Applied Energy 195 (2017) 426438 437
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