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Study of Spiral Effect on Pin-Cooler Simulation in 3D for Enhanced Thermal Management

This report presents a detailed simulation study of a pin-cooler configuration with a spiral separator, assessing its performance and flow characteristics. The analysis utilizes a full 3D model with key geometrical parameters, including oil and PbBi inlet conditions, to evaluate heat exchange efficiency and pressure drops. The findings indicate that the spiral design significantly influences pressure losses in oil flow, while the total heat exchange remains controlled independently of minor geometrical changes. The results also highlight the effectiveness of modified wall functions in optimizing heat transfer.

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Study of Spiral Effect on Pin-Cooler Simulation in 3D for Enhanced Thermal Management

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  1. Megapie Project CRS4 report CEA, Cadarache February, 26th 2002

  2. Pin-cooler simulation Spiral effect study on a simplified 3D simulation

  3. Geometrical characteristics • Pass (h) 85 mm • Height (H) 510 mm • Spiral diameter (Sd) 1.5 mm • Oil annulus internal diameter D 47 mm • Oil annulus width (dr1) 2.1 mm • Steel wall width (dr2) 1.5 mm • PbBi annulus width (dr3) 4.25 mm • Spiral angle over horizontal plane () 30o

  4. Flow characteristics • PbBi inlet: 4/12 l/s at 360 C • Diphyl THT oil: 10/12 l/s at 100 C

  5. Test cases

  6. Pin-cooler simulation Full 3D simulation with spiral separator in the rising oil channel.

  7. Flow characteristics • PbBi inlet: 4 l/s at 360 C • Diphyl THT oil: 10 l/s at 100 C • Power exchanged: 64 kW • PbBi: DP=108 kPa for Dz=1.382 m • Diphil THT Oil (rising column): 170 kPa for Dz=1.402 m

  8. Simulation features • About 2 millions cells, 1.3 million for Oil • Spiral: 15 loops with 85 mm gap • Non matching regions inside oil region and in solid. • Chen variant of k-e model • Wall functions for PbBi • Two layers for Oil

  9. Ultimate changes • Spiral diameter from 1.5 to 1.6mm • Spiral orientation (indirect triad) • Spiral in-lining • Partial account for the 1mm diameter thermo-couple wires • Thermo-couples positioning • Separation of upper LBE region • Main non-matching transition from steel to LBE

  10. Main geometrical parameters

  11. Final mesh characteristics

  12. Run features • Parallel execution on 7 SP3 processors • Typical runtime: 12 hours • Steady state solutions • Variable turbulent Prandtl number • Modification of LBE wall functions

  13. Numerical and experimental results

  14. Oil flow orientation

  15. Wall function and Pr modifications effect • Modified wall functions increase heat exchange • Modified Prt decrease heat exchange

  16. Conclusions • Numerical simulation led to individuate a problem in proximity of the LBE inlet gap. • Total heat exchange is controlled by the global mass flow rates independently of small geometrical perturbations and is extremely well reproduced. • The spiral wire seems to introduce a strong sensibility of the Oil pressure losses to small geometrical perturbations.

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