Numerical Simulation of a Heat Exchanger with Multiturn Piping and Performance Optimization

The heat exchanger in a hydropower unit plays a critical role in ensuring the stability of the unit and improving operational efficiency. This paper conducted a global flow-field/heat-transfer numerical analysis of multi-tube heat exchangers in hydropower units (with 98 tubes) and applied it to optimization research under actual operating conditions. Using a three-dimensional two-phase flow model, this work systematically analyzes the effects of different sand content and particle size on heat-transfer performance, revealing the impact of particle-flow and fluid-flow nonuniformity on heat-exchange efficiency. This research fills the gap in existing studies regarding the analysis of the impact of complex operating conditions on hydropower unit radiators. To address the issues of nonuniform flow fields and poor flow mixing in existing heat exchangers, an improved inlet/outlet structural-optimization plan is proposed. The original cylindrical inlet/outlet is replaced with a square structure, and its area is increased. The optimized structure improves flow uniformity, reduces flow losses, enhances heat-transfer performance by 7.7%, and achieves a significant reduction of 0.53 K in oil temperature. The findings of this study provide theoretical and engineering guidance for the design and optimization of heat exchangers in hydropower units and are of high value for practical applications.