Effect of structural and operating parameters on the energy efficiency of air-cooled heat exchangers

Abstract

Relevance: The energy efficiency of air-cooled heat exchangers directly depends on the structural characteristics of the heat-transfer surface, tube arrangement, degree of finning, organization of the air flow, and the operating mode of the fan electric drive. An irrational selection of these factors leads to a decrease in heat-transfer intensity, an increase in aerodynamic resistance, and higher electrical energy consumption.

Aim: To carry out a systematic analysis of the main structural and operating parameters of air-cooled heat exchangers and to evaluate their influence on the heat-transfer process and energy consumption.

Methods: The study presents a comparative analysis of heat-exchanger tube arrangements, finning methods, elements used to intensify the internal flow, geared, belt-driven, and direct-drive fan configurations, as well as methods for controlling rotational speed.

Results: The analysis showed that increasing the heat-transfer surface area and intensifying flow turbulence enhance heat transfer; however, they also result in higher hydraulic and aerodynamic resistance. Regulation of fan rotational speed, optimal configuration of the electric drive, and control of the blade setting angle were identified as the main approaches to reducing energy consumption and ensuring stable cooling operation. The necessity of integrated optimization of the heat exchanger and fan systems in order to achieve high efficiency in air-cooled heat exchangers was substantiated.