Numerical Analysis of a Solar-Powered Tube Heater

Abstract

This paper evaluates the performance of a solar-powered tube heater that uses air impingement jets to heat steel tubes in the powder-based coating process. To evaluate the thermal performance of the tube heater, two numerical models, ANSYS FLUENT Dynamic Mesh (FDM) and ANSYS FLUENT Transient Thermal (FTT), were developed and their accuracy and computational efficiency were compared. The FDM model analyzed the heat transfer in the tube heater by simulating a moving steel tube with a steady heat source while the FTT model by simulating a steady steel tube with a moving heat source. Results showed the FDM model to be computationally more time and cost-efficient, requiring 4 processors and 4 days to run compared to the FTT model which required 40 processors and 31 days. On the other hand, the FDM model showed a more detailed temperature contour of the tube with higher temperatures on the edges due to air crossflow. However, this did not have any significant effect on the final average temperature of the tube which was found to reach 76oC by both models, consequently reducing the required load of the induction heater by 22% and the Greenhouse gas (GHG) emissions of the induction heater by 2.15 gCO2e/m.